Custom Intake Manifold

[kwhauck]

If everything works out right, I should have a rough 3D CAD model of a lower intake this evening. From there, I can start playing around in CAD some more to develop a new lower intake.

anything?

[bszopi]

No. First attempt failed miserably. Second attempt went a little better, but still didn't give me what I needed. Haven't gotten around to going for attempt #3.

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[kwhauck]

attempt 3????

[bszopi]

Was messing with it last night, although it still isn't giving me the results I was hoping for. I might post what I currently have, and then possibly go for attempt #4. After that, I may just go back to the way I was planning on doing it before...

[kwhauck]

If you could that would be great!! You obviously have better capabilities than me. I am working with a notebook of calculations and formulas and whatever spare crap I can find in my garage for mockup. I would love to see what you have come up with and why it isn't giving you the results you were hoping for (ie. the good, the bad, etc).

Me personally the first set of mockup flanges didn't turn out how I wanted at all and lacked giving me access to bolt the manifold down using stock locations. I have a new design in my head and on scratch paper however that i think could possibly work. I might pick up some aluminum when i'm in the big city today if I can get a deal on a half sheet or some other scrap laying around....

[bszopi]

You are actually further than me.. I am currently using a new tool from Autodesk (which is in development phase) called Project Photofly (http://labs.autodesk.com/utilities/photo_scene_editor/). Basically, it allows you to take standard digital pictures and stitch them together to create a 3D image, which can then be scaled and converted to a DWG for editting in AutoCAD. Unfortunately, I think the manifold is a bad object to try to attempt this with because of the symmetry of it, as well as it not having enough definite points for the computer o accurately stitch the photos together. I went through last night with ~30 images and manually selected identical points on 3 images (4 points per image) to hope to align the images better. It definitely improved the image some, but it still isn't accurate enough to develop a 3D CAD drawing from.

[bszopi]

Here is a screen shot from the editor. Its hard to get a good idea of what all is there. Might have more time tonight to mess with it some more...

[Jonpro03]

cool

[kwhauck]

cool!!!

I am holding off on the flanges for right now. I started hacking at a manifold this afternoon. The idea is to hack out as much as possible, getting as close to the stock injector mounting without interfering. Fine tune with a die grinder. From there fab and weld a box with a trapezoid type top onto the manifold.

progress.......

[SappySE107]

Brad, take the coolant line off and flip the manifold upside down. Maybe that will make it easier to tag the points?

[bszopi]

I guess the bottom, as well as the head mating surfaces are what I need, so flipping it over may produce better results. I will try it out!

[kwhauck]

Well I cut out as much as I could and the spare motor and manifold as well as a variety of injectors and fuel rails have been dropped off at the fab shop. It is in their hands now and will finish it as fast I as give them money! lol

The plans are for a small box plenum to be welded into the stock lower manifold, and then a v shaped plenum bolted above that will just give enough clearence for the fuel rails. I also realized with all those runners gone I can run stubby injectors and give myself at least 1 more inch which will be huge. Initial measurements put me having just at 5" of clearence on a stock hood above the fuel rails. The whipple is right at 5" tall so it will be close!!!

[bob442]

i think you would be better off to take all of the ports off and weld in bungs for the injectors after the fact with custom rails., closing up those ports would be a PITA.

[kwhauck]

i think you would be better off to take all of the ports off and weld in bungs for the injectors after the fact with custom rails., closing up those ports would be a PITA.

I'm not even sure what you mean here...........but the stock injector locations are really as close to the heads as possible. Not much you could imrove on there. As far everything else in concerned. I have eliminated all runner length except for maybe 2 inches on each runner, so essentially I have just 2 inches of runner including where the injectors go before each runner dumps into a box plenum that will be custom cut/fabbed into the stock LIM.

This is where I dropped it off. They have done some top notch work for me before.

http://www.hanksvillehotrods.com

[bob442]

I need a mill to explain any better lol, basically go past the injectors