What are normal charge temps for a WAIC at 75 F ambient?

[Gizmoman]

http://www.frozenboost.com/product_info.php?cPath=216&products_id=1034&osCsid=c061cd8152a1f0429d267916d2b01717

their rad is 13x10x2" is yours as thick? I would think if you open up the flow and your rad is sufficient you should have less intake temps than what you do.

I didn't figure you had room for the longer runners as is, but I still think you would like them.

I do believe that's the same rad and fan I have. I'll work on improving the air flow as suggested. I may even remove the fan as it may actually impede air flow.

True, I would like the longer runners if they increase low end torque. I wouldn't like the "wobbly feeling" of the van though after I cut through the rear frame

[theman53]

FWIW the runners don't have to be straight, you could make them out of C shapes if that would help your situation.

[bbob203]

why not get a 1y/ sdi intake and chop off top and use the runners might that work?
http://www.google.com/search?q=1y+intake&client=ms-android-att-us&hl=en&source=android-launcher-widget&v=133247963&prmd=ivns&source=lnms&tbm=isch&sa=X&ei=PqucUvWsIMKA2gXGu4B4&ved=0CAYQ_AUoAQ#i=4

[745 turbogreasel]

I used  as much air dam/ducting as i could come up with, and  a fan on a thermoswitch, but with a 20 passenger bus, I had a good amount of room to play with.

[Gizmoman]

If I were to get an "unmodified" intake, in case I want to replace my "modified" one for my 50* AAZ. Would this one work for it?

from this topic http://www.vwdiesel.net/forum/index.php?topic=31782.0

It looks like it has similar "D" style ports as mine and it does have "runners" of a sort. According to some recent suggestions, runners are good for low end. My original one was more of a rectangular box casting with a port on top and a bolt-on 90* elbow - didn't seem to be much thought into it regarding air flow but, I'm no expert.

Anyway, not sure if I'll go that route, just keeping my options open. The one I had seems to be tough to get here in the states.

[theman53]

That is one of the PD intakes and it would work. I honestly don't see a huge difference over stock ALH or 1.6TD intake, but it would be better. As good at tig welding that you are I would think you could get any 1.6 or 1.9 intake and make something. The 1.6 you could weld and port to the D shape, the 1.9 would be ready to go up with. Time would be a factor but those PD intakes go for 150.00, so cost would be less - time factor.

[Gizmoman]

That is one of the PD intakes and it would work.

So, are you saying you've run both and this one is better?

I honestly don't see a huge difference over stock ALH or 1.6TD intake, but it would be better. As good at tig welding that you are I would think you could get any 1.6 or 1.9 intake and make something. The 1.6 you could weld and port to the D shape, the 1.9 would be ready to go up with. Time would be a factor but those PD intakes go for 150.00, so cost would be less - time factor.

Thanks for the nice comment on my tig skills but I find them a bit embarrassing - but effective . I'd rather have the proper D ports, and modify from there if needed to fit a possible Frozen Boost intercooler.

My original used to look like this



Not necessarily a technical marvel.

[theman53]

I have not run both, but from the looks of the design of the PD it is a marginal upgrade IMHO. It has some runner length but since you can tig why not go for the ideal.

[8v-of-fury!]

from this topic http://www.vwdiesel.net/forum/index.php?topic=31782.0

That is one of the PD intakes and it would work. I honestly don't see a huge difference over stock ALH or 1.6TD intake,

I have not run both, but from the looks of the design of the PD it is a marginal upgrade IMHO. It has some runner length but since you can tig why not go for the ideal.

The PD150 intake comes off of the 150hp Pump-Düse engine. It is, in stock form an intake manifold that will flow a proven minimum of 150hp worth of air in to the 1.9 engines. Granted, other things changed to achieve that 150hp so you are not just going to bolt this on and make an additional 50-60hp. The ALH intakes were designed for 90hp, and the 1.6 MF intakes were designed for 68hp.. Clearly, because we trust Volkswagens engineering so much the 150hp manifold they designed is by far a better choice when comparing stock manifolds. 

No offense to Gizmoman, but how can a guy in a garage hacking up manifolds and welding on runners be ideal?

[theman53]

I have built it, I guess would be the best answer. If you read about it, it is fairly basic, but to sum it up quickly the longer the runner the faster and better peak torque you will have. If you really get into it you can tailor it to a very specific RPM point. Look at the airflow dynamics and how even though it is air, it travels like a sound wave. The diameter of the runner and the plenum size has more to do with the flow, and to flow 150hp worth of air it is not that hard. I am not talking about HP I was trying to help his low RPM torque issue. For total HP a larger diameter and shorter runner intake is better than what I suggested.

I guess take it for what you will Gizmo, but have built 2 engines that I am guessing had a bunch of power and have modded several stock engines for power gains. YRMV, but I have experience in this and I know what I said is accurate. The PD manifold would be an improvement, but if you figured out the math on the runner length you will be able to easily build a better manifold to what you want. You just have to know what you are doing.

[Gizmoman]

That is one of the PD intakes and it would work. I honestly don't see a huge difference over stock ALH or 1.6TD intake,

I have not run both, but from the looks of the design of the PD it is a marginal upgrade IMHO. It has some runner length but since you can tig why not go for the ideal.

The PD150 intake comes off of the 150hp Pump-Düse engine. It is, in stock form an intake manifold that will flow a proven minimum of 150hp worth of air in to the 1.9 engines. Granted, other things changed to achieve that 150hp so you are not just going to bolt this on and make an additional 50-60hp. The ALH intakes were designed for 90hp, and the 1.6 MF intakes were designed for 68hp.. Clearly, because we trust Volkswagens engineering so much the 150hp manifold they designed is by far a better choice when comparing stock manifolds. 

No offense to Gizmoman, but how can a guy in a garage hacking up manifolds and welding on runners be ideal?

Certainly no offense taken 8-V, I appreciate your perspective and find it very informative which is why I'm here. I really don't want to get into making an entirely custom intake again and if this will provide 150 HP of air flow (given other items are adjusted to suit), I'm nearly there.

Does anyone have the following dimension?

I need to see if this will clear the deck lid in the van.

My plan at this moment is to increase the diameter of the ports on my existing Laminova WAIC. If that lowers my IAT to near ambient (which I doubt it will), I'll see what it does to my EGT's. If they are still way too high, I'll up the K14's boost to 18. However, if the EGT's drop a fair amount, but I still am getting IAT temps in the 150 range, I'll go for the PD150 manifold and a Frozen Boost IC. If there's not much change after that, It's time to consider a VNT 17 and mechanical boost/vane control set-up similar to libby's - ugg!

[8v-of-fury!]

8" exactly Gizmoman.



This other side view does the intake manifold much more justice, as you can see it is somewhat a constant velocity stack the whole way down in to the head. Goes in and slims down the whole way down.

[libbydiesel]

Looks more like 7" to me.

[8v-of-fury!]

Show me your intake picture and we will compare. 8" exactly.

[libbydiesel]

Mine is way bigger.  How about I show you yours instead...  Gizmo asked for the measurement between the bolt holes and the outer edge of the inlet.  It looks like the end of your tape is hanging over the end of the manifold by a fair bit with the 8" mark right on the bolt holes.  OK, maybe 7-1/2"...  Definitely not 8" unless something in your photo is seriously warped.