Manifolds

[macsdub]

i like twisting my own
its better than the commercial stuff  man

[935racer]

dave,
don't know if this is the right place to post, but if you're having a bunch done up, put me on the manifold list....no rush as you know, but I'll pick up whenever they're ready (also, let me know when you have an intercooler for mock up )

I'll put you down for an intake manifold phil, the exhaust manifold I have designed won't work as it will hit thea lternator for your application. We'll have to go with something like a kinetic 8v cast manifold that sticks the turbo straight out, not down like mine. Give me a call at the end of the week about the intercooler I will likely have an extra than.

[935racer]

i'm kinda curious what's up with making manifolds, they already are available for the gassers, and, they will obviously work on our cars...

For the counterflow 8v engines all I know that are commercially available are log manifolds and cast manifolds. I am building tubular manifolds, equal length primaries, and a pulsed firing sequence, comparing these manifolds to the currently available gas versions is like comparing a ford taurus to a w123 chassis mercedes benz.

[935racer]

Your machinest must have a 5 axis mill. The transition from round to oval will be tricky to machine without one. I suppose it could be picked out with a ball mill on 3 axis equipment but it would cost alot, machine time =  money. I'd be tempted to squish the tubes a bit to get the transition, the result would be smoother and the machining WAY easier. Better clearance from the intake as well.

5 axis mill yes. I have made manifolds by simply squishing the tubes to match the oval port, my beef with that is that the match up is not perfect, and it does cause more turbulence than you would think, I have been playing around on the flow bench with these things quite a bit lately, these manifolds won't just be just a bunch of weld els thrown together with a collector and a couple flanges in the space given, they are being carefully engineered for maximum performance and quality.

Here is a different shot of the exhaust flange:

[935racer]

i like twisting my own
its better than the commercial stuff  man

I like making my own as well, but it is due to no one else making them to my standards more than anything. These arent just some commercial cast manifolds, or cheapo "ramhorn" or "log" manifolds. I am trying to set new standards. The economiccal intake manifolds are the only manifolds I will make that aren't absolutely perfect, they will be a million times better than the stock intake manifolds, and of the same if not better flow and quality of vw gasser intake manifolds. I have a perfect intake manifold in the works, the cost is high to make them, but they offer balanced runners within nearly 1cfm, incorporating 3 plenums. The exhaust manifolds are just cherry.

[QuickTD]

You're fortunate to find a shop with that sort of equipment willing to do small jobs. The staggering payments on a half million dollar lease usually make the owners whores to the aerospace or mold industries...

 I love old circa 1975 CNC's, no payments. Allows me to take the occasional Sunday off...

[935racer]

You're fortunate to find a shop with that sort of equipment willing to do small jobs. The staggering payments on a half million dollar lease usually make the owners whores to the aerospace or mold industries...

 I love old circa 1975 CNC's, no payments. Allows me to take the occasional Sunday off...

A God send no doubt, I am definately blessed to have someone willing to do these things for me and for actually a very very reasonable cost. I have been looking at old cnc machines myself, its still a few years down the road before I would buy one, but I love to dream.

[Kudagra]

I think Im going to piss myself if I dont see one soon.

...That and Ive been drinking ALOT of water.


Thanks for keeping us all up to date.


"Will this be the next "Have To HAVE" Mod on the list?"

It is for me anyway.

[935racer]

I think Im going to piss myself if I dont see one soon.

...That and Ive been drinking ALOT of water.


Thanks for keeping us all up to date.


"Will this be the next "Have To HAVE" Mod on the list?"

It is for me anyway.

Trust me,no one wants these flanges to show up at the shop more than me. I am dying to get these things under way, they are much needed for those of us looking to step it up in the vw diesel performance scene. And yes, its a 'have to have' for the high performance vw diesels

[DVST8R]

Get Eazy E to row himself to shore, and get the manifolds done. Ah the bennifits of riding bike with a guy who decides to become a cnc operator...  

[935racer]

Get Eazy E to row himself to shore, and get the manifolds done. Ah the bennifits of riding bike with a guy who decides to become a cnc operator...  

Yeah Easy E is doing pretty much all the cad work, unfortunately he cant cut the flanges for me, they are getting cut very far south of here. Hence it'll be three to 4 weeks before I get the flanges cut.

[Kudagra]

Can I have one fabbed up to work with this?

[935racer]

External wastegate yes, that particular one not likely, unless you provide a flange. That wastegate looks old and sketchy. I have good luck with these models, which I have flanges for:

http://www.kineticmotorsport.com/catalog/tial-38mm-wastegate-p-29.html

[jtanguay]

is that some ancient exhaust bypass/egr system???

[Kudagra]

Its from a Audi 5000. Free...well sort of. I did some bobcat work for it.

Its nice that the local european car scrapper has a really old bobcat.

And I can still get diaphrams for it.