side project i'm working on (intake manifold)
 

well, i've been taking welding at community college for a few quarters now.. i've been mess'n around with several different projects..
heres one i'm finishing up.. GSR flange/runners with 4.5" tube plenum.. i've got a bigass TB i'm gonna mount on it.. i might change my mind tho.. we'll see. i've still got some more grinding/sanding to do inside the runners. and then i'll weld on the rest of the tube.. i'll keep this updated.

http://img110.imageshack.us/img110/8382/gsrim0wj.jpg

Re: side project i'm working on (intake manifold)
 

so that used to be a GSR intake mani and you chopped the plenum off correct? I think this is the same sort of thing jeff did on the twin turbo crx. Betcha its really cost effective :y

Re: side project i'm working on (intake manifold)
 

yeah, just had the GSR IM sitting in my garage, bought some scrap tube, cut the runners at bout 8 inches, then put the flange/runners on a mill, turned the mill head 90 degrees, got a cutter set at 4.5" diameter (same diameter as the tube), and cut the radius into the runners for a perfect fit(length to the radius is 6"). took plasma cutter and cut the tube length wise.. tacked the half tube to the runners, then scribed the outside of each runner onto the tube half.. cut the tacks.. then took a pen and drew inside my scribe marks so i can cut with plasma cutter. then tacked on the runners again and started grinding to match the holes to the runners. then i V grooved the inside of each runner with the tube half.. so i would get good penetration when i welded the insides.. once the welding was done, i started grinding again and got it all nice.. the worse part of this job is the gsr IM flange and runners was used so they were "contaminated" .. i cleaned the ---- out of them.. hot tank and everything.. but still welding aluminum any contaminant will make welding a bitch.. the welding on the insides of the runners went alot better than the outside of the runners :-\ so i ground off the oustide welds so it wouldnt look bad LOL.. i'll post pics of it later when i get it all done.

Re: side project i'm working on (intake manifold)
 

a little update, been working on it between other projects. getting closer to being done

http://img19.imageshack.us/img19/6800/gsrim5qv.jpg

Re: side project i'm working on (intake manifold)
 

keep posting pics about this....i wanted to do either this or port my stock GSR manifold since its just sitting around collecting dust......how are you planning to hook up the sensors to it though??

Re: side project i'm working on (intake manifold)
 

i think you should make the cylinder 1 side of the plenum go even further past the last runner, so the air has somewhere to exercize.

Re: side project i'm working on (intake manifold)
 

LOL fook,
thats there for plenum volume.

Schister66,
only sensors that will really need to be on there would be the intake air temp sensor and the intake air control valve, i havent decided where i'm going to put the IAT, the IACV i've got an idea how i wanna do it, but very hard to explain, it'll be in a somewhat "stock" location but i dont think i'll have it hooked to the throttle body.. too much work, i might use some kinda valve cover vent filter for the air coming in... its either that or not even having the iacv connected to the plenum

i'm going to use a GM LS1 73mm TB so i've gotta figure out what to do about the throttle linkage. it has a 5v reference voltage for the TPS so i just need to find a GM TPS plug and wire it into the harness.. crome itb tools allows for different tps voltage correction.. so if i have problems with the gm tps, that should solve it. (actually i've got my own rom custom coded for normal operation with only mods for tps correction. ;) but the crome itb tps correction would work for someone else.

Re: side project i'm working on (intake manifold)
 

edelbrock sells a 'mustang 75mm throttle body' that is setup for a honda's out of the box, for an extra $20 they even sell an adaptor plate that you could use for a flange. sweet work tho. i'm trying to decide on a manifold still.

Re: side project i'm working on (intake manifold)
 

how much does it cost tho? i got my 73mm GM TB for a very reasonable price brand new.

Re: side project i'm working on (intake manifold)
 

looks good, but you should try to see it it fits, it sure looks like it will hit the brake master.

Re: side project i'm working on (intake manifold)
 

my teachers at school said that your not supposed to make the top of the intake mani smooth like glass like most people do i didnt pay to much attention but something about vortex or something like that maybe something else too....but either way he said you want to make the intake the way i just said and the exhaust glass like...

Re: side project i'm working on (intake manifold)
 

That's correct - the best way to merge a runner into a plenum is by using a bell (or "velocity stack")... before people argue that it doesn't make a difference on forced induction engines, consider the fact that you're pressurizing your manifold.... not just adding volume from the turbo. Most airflow modifications for NA engines can be adapted to forced induction engines and the resulting power will only be greater. :6

Colin

Re: side project i'm working on (intake manifold)
 

i set the plenum on my race hatch's gsr motor, it'll be really close, :(.. i'll probably do a little cutting on the end, its all good tho,

i find it funny how people think that having polished runners is bad. i agree that the intake ports shouldnt be polished.. and here's the reason, you introduce fuel to the air where the intake manifold bolts to the head.. so at the beginning of the intake port on the head. the problem with a polished port is that the fuel air mixture tends to separate and the fuel gets stuck to the walls on a polished surface, thats why they want some abrasion on the intake port. the runners on the manifold dont have any fuel flowing through them, so being polished can help. my runners arent polsihed, they're smoothed with 150 grit flapper wheel.

about having velocity stacks inside a plenum, yeah thats all fine and dandy, if you are making custom runners and have the right materials.. but when you're using existing factory runners, you show me how to make velocity stacks inside the plenum to mach them???? any of you ever seen the inside of a JG enginedynamics sheetmetal intake mani for the ITR or GSR heads? look just like that on the inside. and those JG IM's work really well.

this intake manifold is going for NA.. unless you think a 73mm TB is good for boost?
either way it'll never see boost while i have it, its for a GSR head so wont work on my turbo LS project.
i'm just building this for fun.. for the welding experience in class, and maybe i'll make some money on it at some point.;)
but basically just building it for the challenge. if it works great, if not, no big deal, it didnt cost me anything, and i got good welding experience on it with the contaminated gsr runner material.

thanks for the comments tho :)

Re: side project i'm working on (intake manifold)
 

Q45 TB?

Re: side project i'm working on (intake manifold)
 

Looks kinda like mine :) Man did that leave a pile of shavings in the garage.
http://www.eville140.com/starlet12/intake1.jpg
http://www.eville140.com/starlet12/intake2.jpg
http://www.eville140.com/starlet12/intake3.jpg

Later
Randy

Re: side project i'm working on (intake manifold)
 

your a bitch. nice ride, im jealous :y

Re: side project i'm working on (intake manifold)
 

Randy thats sweet! what car/motor is that?

myAE86turbo,
the TB is from a GM LS1 marine engine.
http://webpages.charter.net/richardk...3mm50mmTBs.jpg

Re: side project i'm working on (intake manifold)
 

The car is a 1982 Toyota starlet, the motor is a toyota 2rz, 2.4l twin cam

That LS marine throttle body looks nice, I have been looking for a Q45 tb but they always end up going for quite a bit of change.
I really like this throttlebody, but send $250 to somebodynamed Cheap Chang in Bangkok, Thailand with no feedback is a bit scary.
http://cgi.ebay.com/ebaymotors/ws/eB...RK%3AMEWA%3AIT

Later
Randy

Re: side project i'm working on (intake manifold)
 

Ahh, holy crap... I almost thought that was a 3TC at first. Brought back memories of my first car, the '82 Corolla little red "Radio Flyer" wagon. ;D

Colin

Re: side project i'm working on (intake manifold)
 

Well it started out where I was going to put a 2.3 ford in it, then I had a 3tc in the car and just about to the point where I could fired it up. Well at the last minute I decide to go ahead and go with the 2rz and try for some stupid hp. My goal is 600 at the wheels any more than that wouldn't make me upset :) Mainly just for dyno days, and back it off to 400 or so for the track. 400 should still make for pretty easy high 10's in the 1/4. Rearwheel drive owns :)
Here is a link to my old 2.3turbo rx7
http://www.eville140.com/rx7.html
If this car doesn't end up considerable faster than it I will drive it off in the river. lol

Later
Randy

Re: side project i'm working on (intake manifold)
 

your always up to something aren't you rick? ;D

looks great.

Re: side project i'm working on (intake manifold)
 

LOL i was gonna put it on the Hatch at one point, but wont be done in time.. plus it'll take a special rom and more tuning LOL i'm just gonna get the hatch tuned so u can come and get it :)

Re: side project i'm working on (intake manifold)
 

that's what i have lived my whole life to hear ;D.

just tell me the word and i will be on my way :y

Re: side project i'm working on (intake manifold)
 

Cheap chang got some nice stuff there. Let me know if they're legit. And oh, if your car wont be as fast as your old rx7, you are welcome to crash it in my garage... ;D

Re: side project i'm working on (intake manifold)
 

eville - if you're interested in an original TRD seat for kp61/te27. let me know i have one, i was gonna put it in my starlet, but it's just sitting now.