Time to build a new intake manifold..

[RabbitJockey]

yes it is odd the amount of people that will leave popcorn welds... 5 minutes of grinding and no one will ever know how horrible it used to look.

sweet manifold i want a similar one, its really nice to hear a before and after comparison of how crappy the stock manifold is haha.  i kind of wonder if the dual plenum manifolds on these little engines would make any difference at all.  but hey while you were at it why not make it dual plenum right, surely it won't hurt.

[R.O.R-2.0]

That's great, glad it worked out. What would you say the before and afters were for EGT's and cruzin boost?

it used to run about 700 cruising. now it runs 800-900 going up hills with 8 psi.

used to cruise at about 5psi, now it makes about 3-4.. not a big drop, but enough that i noticed it.

and, it used to make 7-8 psi no matter what, even wide open throttle, with wide open vanes, it usually only made 7-8.. well, i got it to make 15 with the vanes open yesterday..

[RadoTD]

Awesome work, Kevin! That manifold turned out awesome!

I'm going to go right now to cut apart my manifold to make a new one, very similar idea to yours. I have an idea that might work to make the upper plenum tapered with very limited tools though I'll see how it ends up turning out though. Worst thing I can do is wreck a piece of aluminum tube and have to buy a new one

[R.O.R-2.0]

Awesome work, Kevin! That manifold turned out awesome!

I'm going to go right now to cut apart my manifold to make a new one, very similar idea to yours. I have an idea that might work to make the upper plenum tapered with very limited tools though I'll see how it ends up turning out though. Worst thing I can do is wreck a piece of aluminum tube and have to buy a new one

if you need more pics of it, or more of a detailed "how-i-built-it" type of list, feel free to ask.. ive got quite a few pics of it, and if i dont have the pics you are looking for, then i can pull it off in like 10 minutes..

the manifold REALLY DID turn out awesome, and im not trying to pat myself on the back either.. everyone who has actually seen my manifold in person, has not had a SINGLE bad thing to say about it. most people cant believe that I BUILT IT.

i used a band saw, and a welder. that was it. well, a grinder to clean up the metal.. i built this in my HOME shop, not at the school.. the turbo header was a product of the college..

i cut the BOV off as well, and welded a piece over where it was. next time i would just use a LATER model TD intake..

[theman53]

Factory BOV, and secondary manifold inlet are now both deleted..



getting ready to make it a dual plenum

Kevin,
    How tall can you go before issues with the hood on the MK2? What is the height from the bolt holes or another point such as top or bottom of the ports that you have. I am going to build one soon and need to know.

[theman53]

Also with the height question that I still need...Did you use 2.5" ID pipe and if so pm me the details as I have a formula for this and want to see if yours fits in the range.


Anyone know where to get horn shaped aluminum tubing. Like the velocity stacks for a carb only 1-3/8" diameter?

[745 turbogreasel]

Harley stacks?

[theman53]

Those are crazy epensive, but a possibility.

found this but also pricey.
http://www.summitracing.com/parts/SUM-G3029/

[theman53]

I really want that, and I am sure you aren't giving it away...

What I can give away is some hillbilly cheap info. If you want velocity stacks then look no further. On the cheap and all aluminum. You will have to do some fab work, but if you are building an intake that shouldn't bother you.

Be warned this should make you LOL, but I am serious, this is what my intake will have in the plenum...

http://www.culinarydepotinc.com/p-31242-alfa-022rt-34-stuffing-tube.aspx

[R.O.R-2.0]

I really want that, and I am sure you aren't giving it away...

What I can give away is some hillbilly cheap info. If you want velocity stacks then look no further. On the cheap and all aluminum. You will have to do some fab work, but if you are building an intake that shouldn't bother you.

Be warned this should make you LOL, but I am serious, this is what my intake will have in the plenum...

http://www.culinarydepotinc.com/p-31242-alfa-022rt-34-stuffing-tube.aspx

lucas, im sure those are some super thin, soft alloy.. i doubt they are going to work that well..

[theman53]

I have had them in my hand and I would agree they are somewhat thin, but still over 1/16". I am not using them for the entire tube, I am going to use them for the bell end only, welded to a .083" wall 6061 alloy tube. It will work fine. I wouldn't 100% trust them for a structural part for years of service, but they are stout enough I bet it would work for a while. You would be surprised at the force to stuff some sausage

[R.O.R-2.0]

I have had them in my hand and I would agree they are somewhat thin, but still over 1/16". I am not using them for the entire tube, I am going to use them for the bell end only, welded to a .083" wall 6061 alloy tube. It will work fine. I wouldn't 100% trust them for a structural part for years of service, but they are stout enough I bet it would work for a while. You would be surprised at the force to stuff some sausage

that would work, just using them for the actual inlet trumpet..

i thought you were going to use them for the runner and all tho..

[theman53]

Runner and all would be way too small at 3/4". I think they would hold some weight, but I am into trusting the 6061 that the runners will be made of more. I dont know what alloy the stuffing tubes are made of, but it is stout. I am kinda impressed with it...alas it will work for the task at hand for sure.

[ORCoaster]

And as an added bonus when you are out hunting you can make sausage with your engine.  Just going to taste a little, well like diesel.

[RabbitJockey]

I think onced I am ready for a better intake I will flip the exhaust manifold and get a stage 1 scientific rabbit manifold, they're only 125, can't beat that