tooter's manifold adventure...

[tooter]

Originally Posted by baseballfan416

Tried to search through this thread for comments on gas mileage to no avail... Any significant difference either way?

There was a slight increase but it was not significant. I took the mileage readings from the last 699.6 miles @ 19.508 gallons before installing the tooter,and the average came out to 35.86 mpg. I didn't count the fillup that had the stock dyno runs in it so that the average wouldn't get dragged down.

Then I took the following 514.0 miles @ 13.133 gallons running with the tooter. Also not counting the fillup that had the the dyno runs, and the average is 39.13 mpg. Not exactly in hypermiler territory.

So even with the peak horsepower and peak torque being essentially the same as the stock manifold, the comparative dyno runs clearly show that the tooter underperformed the stock manifold under wide open throttle conditions. However, it does work very well in normal every day partial throttle driving conditions. When you let out the clutch taking off from a full stop it hardly takes any throttle which is really nice when driving in traffic.

[baseballfan416]

39 vs 36 = about a 7-8% gain (3 of 36 = 1/12th = 8.5%). That's pretty legitimate!

The reason I'm intrigued by this is because here we have a product that was essentially taken off of a 1.8liter corolla engine (correct me if I'm wrong). That engine, in it's time, was rated 30city 40 or 41hwy mpg? Combine the better "breathing" capacity with a lower displacement and I think this could be of particular interest to the hypermiling crowd. In a way, you don't necessarily want more power to get better mileage, but rather you're trying to make the engine run more efficiently. Hence the -1hp +1tq is an afterthought if it improves overall drive-ability.

If I had the money, I would get an MI pulley, some sort of an intake manifold gasket (to lessen heat soak), this product and either keep the stock tb or get the mystical corolla tb that everyone is so infatuated with. Combine that with an injen intake (assuming anyone ever responds to my wtb thread) and I bet I could break 50-52mpg in the summer (44-46 avg this past summer).

Of course, this would all cost about $700+ so even with a 5% gain in gas mileage, I'd have to drive the car 10-14 years to make up the difference in saved fuel cost.

[tooter]

Originally Posted by baseballfan416

39 vs 36 = about a 7-8% gain (3 of 36 = 1/12th = 8.5%). That's pretty legitimate!

It would only take about $5,250 in gasoline purchases to pay for the cost of a tooter... without the shipping!

The reason I'm intrigued by this is because here we have a product that was essentially taken off of a 1.8liter corolla engine (correct me if I'm wrong). That engine, in it's time, was rated 30city 40 or 41hwy mpg? Combine the better "breathing" capacity with a lower displacement and I think this could be of particular interest to the hypermiling crowd.

The slightly improved mileage was an unexpected consequence. I was the most concerned with losing driveability at low rpms because the ~20% larger runners. But they are also slightly longer than stock which I think helps some. The tooter would likely work well under a forced induction situation...







You never really know what's going to happen whenever you adapt something to an unintended purpose. It's a total crapshoot.

I'm picking up the rest of the flanges on Tuesday, and then they're going to start on machining the adaptors.

[packetrace]

Am i the first to have confirm to the purchase of one tooter :D?

[tooter]

Yes... you're the first.

[tooter]

All of the tooter manifold flanges are done now so I can start putting them on the manifolds...



The manifolds are all in various stages of being cleaned. They all basically looked like that dark dirty one as they're 14 year old junkyard parts, many from crashed vehicles. They all have scratches and dings, but look pretty decent when they're all cleaned and blasted.

[ljming99]

Manifold'mania

Originally Posted by tooter

All of the tooter manifold flanges are done now so I can start putting them on the manifolds...



The manifolds are all in various stages of being cleaned. They all basically looked like that dark dirty one as they're 14 year old junkyard parts, many from crashed vehicles. They all have scratches and dings, but look pretty decent when they're all cleaned and blasted.

[tooter]

With the flanges done, the machining on the adaptors will be starting when I get these larger gaskets so that the adaptor design can be altered to fit them.



This Corolla gasket is larger then the Yaris one and allows for a 51mm bore. I decided to make just one adaptor which will fit either a 1NZ FE or a 1ZZ FE throttle body. This will allow for an easy upgrade without needing to change anything else.

[tooter]

The larger Corolla throttle body base gaskets arrived today...



This will be much simpler with just one part that fits both throttle bodies. Now the rest of the adaptors can be machined. Tooter two is with the welder and should be ready tomorrow. Then it goes to the bead blaster...

[tooter]

The throttlebody adaptors might be done by the end of next week, and tooter two is all welded up and made it into the blasting booth...

[tooter]

Looks like others have also been adapting manifolds. This is an adaptor to mount a 2zz manifold onto a 1zz engine...



The stock 2ZZ engine makes 180 horsepower.

[baseballfan416]

wait... so is this your next venture? making a corolla xrs manifold fit the yaris? dooood!

[tooter]

Originally Posted by baseballfan416

wait... so is this your next venture? making a corolla xrs manifold fit the yaris? dooood!

I doubt it...
I still don't have a completed 1ZZ manifold yet, as the newely revised adaptors are still in the process of being machined. So far all I have is the running prototype on our daily driver. It's interesting that others have been doing the same manifold adapting idea.

[tooter]

Finally... one completely finished manifold...
The bead blasting put a nice low luster finish on it and made the welds look a lot better by making all the surfaces take on the same evenly blasted texture. I even blasted the adaptor so that it now has a matte finish similar to the throttlebody...









Tooter #2 one now becomes the daily driver tooter because it had the worst dings in it. They're only cosmetic and are barely visible when looking low from the front, but it's still not fit for sale so I don't mind keeping it for our own use.

I'm still waiting on the adaptors which should be ready any day now. Tooter #3 is ready for the welder, and tooter #1 is going to the blaster.

[CrankyOldMan]

Damn, that's sexy! It's like car pr0n...

[Viperoni]

Looking good!

[b20vteg]

sexy!

[tooter]

I bought a Simota intake from Buddy Fan (Thanks, Buddy ) shortened and bead blasted it to match the manifold. And am waiting on a silicone adaptor to finish it off...



Test fitting it into the throttlebody...