Pics of my newly made "log style" intake and IC install.

[Sierra94]

Thought I´d share some pics of my newly made intake.
I´m finally going to fit an intercooler to my M-tdi so I thought I might just go ahead and make myself a new intake while I was at it.

I hardly have any experience in welding aluminum with my old Tig welder but how am I gonna learn if I never try?  

It´s gonna be glass beadblasted and painted before mounting it on the engine. The slit inside is slightly tapered towards the end.

Well, here are the pics:

[R.O.R-2.0]

does that even fit the engine?

i tried doing that, and it hit the timing belt cover, and the charge piping would have hit the strut tower..

heres my engine, with both manifolds mounted..



and a few shots of just the intake..







good job tho.. you might have either turned your heat down tho, or welded faster.. yes, i know, cast aluminum is HARD to weld nicely..

[Sierra94]

My engine is longitudinally mounted, and the pipe is gonna be cut to the right lenght and joined with a slight angled pipe once I start mounting the intake in the car.

Yeah, I was a bit high on current but the cast intake wouldn´t melt otherwise. And the pipe being in such thin material. But I´m pretty satisfied with it being one of the first times ever to weld aluminum  

Thanks for your comment, always nice to share something if you get feedback one way or another. If you click the pic of the mazda in my sig you can se some pics of the setup.

[bbob203]

What kind of exhaust mani is that kevin? is that a vnt turbo?

[Henk]

manifold looks very nice, I couldn't weld ally that well anyway, and i'm sure it does the job.
Will be interested to hear if it makes any difference  compared to standard

Looks like a GT2052V turbo like i have ^

[R.O.R-2.0]

What kind of exhaust mani is that kevin? is that a vnt turbo?

its a Street Toys 2000 tubular "space saver" header.. its been modified to fit my setup tho.

and yes, its a VNT, a GT2056V, basically the same turbo used on the V6 TDI engines.. GT

2052 is basically identical from the outside tho..

the upgraded intake DEFINITELY makes a difference over stock..

my EGTs/boost went down while cruising down the road..

[Sierra94]

I will surely notice a huge difference since I'm also adding intercooler to my setup. I've only used water/meth injection soo far. Now I will run this new intake along with ic and water injection.

If you look at this pic you will see the restrictive intake I run now:
http://www.garaget.org/?car=81419&image=2779262

[Henk]

Ah I imagine so then! Need to look into water/meth myself.
By the way i love your mazda; very cool 

[RabbitJockey]

nice truck, u don't see those trucks hardly at all in pennsylvania anyway, but we are a very rusty area.  not as bad as ohio, michigan and canada tho!

[Sierra94]

Some new pics of the IC install. (Sorry for the bad picture quality)
The IC is from a Saab 900.
Just missing a pipe and some clamps. And I have to make spacers for the radiator mounts.

[R.O.R-2.0]

they make those intercoolers in an all-metal version too..

blackstone builds it for them.. identical to your plastic tanked model, but all aluminum..

[8v-of-fury]

Apparently from my readings, the Saab plastic tanks will hold up to ~20psi. In reality? There is no need to go above this number off boost pressure, unless your running some awesome setup to cool that air it is unnecessary heat and hurts performance.

Put a strap around it if you want 18-20 reliably.

[R.O.R-2.0]

Apparently from my readings, the Saab plastic tanks will hold up to ~20psi. In reality? There is no need to go above this number off boost pressure, unless your running some awesome setup to cool that air it is unnecessary heat and hurts performance.

Put a strap around it if you want 18-20 reliably.

my intercooler (the plastic tanked one) cracked a tank.. i didnt run much past 25psi thru it.

[Sierra94]

I´ll have to look out for an all-metal one . My max boost pressure peaks at 28 with vanes fully open. (I don´t have a vane control system setup yet) I guess I´ll be seing higher pressures with faster variations once I get a control system setup.

[R.O.R-2.0]

I´ll have to look out for an all-metal one . My max boost pressure peaks at 28 with vanes fully open. (I don´t have a vane control system setup yet) I guess I´ll be seing higher pressures with faster variations once I get a control system setup.

28psi with your vanes OPEN?!

holy crap..

you should see no higher pressures with vane control..