We have made great progress today. I am taking a break from the fabrication side of the project as Trent is doing the final welding on the runners/stacks/plenum and end plate. I will be putting the finished intake on the flow bench today just to see how it flows and move the throttle body inlet around to see what effect it has on the flow in the runners/plenum.

Then we have to build fuel rail mounts and put all the fittings in for boost/vaccum and a dipstick mount.

I'd like to think by tomorrow we will have the first intake on the car.

Also, after putting the intake flange up to the head the entry to the head and the 10 degree angle do not match up very well at all. It was decided to leave the runner straight into the head.

I guess this is going to come down to runner length, velocity stack, runner dimension and plenum size to see if we've gone in the right direction or not. After I test it the next change will be to the plenum size, I want to go much smaller. It is approximately 250 cu in now. About 5 times that of the stock plenum. Many others are in the 300+ cu in range.

Just took the first measurement of the runners, they are as long as I can get them, 7.5". That's from the plenum floor to the head. I'm happy with that as I wanted long runners.

 

When are we gonna see pics of your new child Dave?

Even if he is not too cute we will understand since it's a prototype.

 

Oh, it's pretty actually! I used a stock head flange, that's the ugliest part of it and even that doesn't look bad. I'll try to post pictures today.

 

dang you move quick dave! i didnt expect you to have a prototype for at least a week. looking foreward to the pics and results.

 

Alright the intake is finished and I just got back from the flow bench. I do not have pictures of the intake completely welded up with the throttle body on it, we got pushed for time but you will get an idea what we've been up to by these.







Also for the flow bench numbers. These tests were done with our 65 mm throttle body on the intake just like all the others.

#1, 324 CFM (-1%)
#2, 329 CFM
#3, 327 CFM (-.006%)
#4, 321 CFM (-2%)
Total CFM 1301
The runners are 7.5" long
The Plenum is about 250 cu. in.

So we ended up with the most balanced flow of all the intakes and by quite a margin. The total flow I am shocked to see as low as it is. The runner with just the velocity stack on it (runner was short, total length from head flange to top of velocity stack was about 4") flowed 382 CFM. So we lost about 57 cfm per runner by putting the plenum on it and the throttle body.

As I have seen the flow bench isn't directly relating to what we see on the dyno so I am not getting discouraged or my hopes up. Just staying open minded. Tomorrow we will put all the vacuum ports in and get it mounted up and put on the dyno.

 

Wow that looks great

 

Lookn good, dyno results of the new intake should be interesting. Hard to tell from those pics but do the runners have any taper?

 

dave...by having a large dA (change in cross sectional flow area) your pressure drops, flow stalls, and you loose the momentum/inertia of the air entering the plenum.

This stabilizes flow (cylinder balance), but doesn't help you in terms of increasing overall flow.

 

so basically as the air enters the plenum the velocity drops making it easier to turn into the runners?

 

that looks freakin sweet!

 

Great job and thanks for doing this for all of us bud! You never stop.

 

Very cool! Can't believe you built that thing so quick!

Who wants to make predictions on how that sucker will perform?

 

Very nice.

Is that ~9"- 10" of runner length?

do you plan on making this into your expandable runner set-up?

 

The runners have a very slight amount of taper just before the head flange just to make them mate up to the head port. The runner itself straight.

I cannot make this one an adjustable runner, obviously, because the runners are angled. The measurement from the plenum floor to the head flange is 7.5".

RTernie, not sure I understand completely. Don't be scared to explain it on a kindergarten level

The plans are to run the intake and see how it does at 30 psi and 41 psi tomorrow. Depending on the results I will decide where to go from there. If it just completely sucks there's a good chance I will say **** on it and not build another one. If it looks decent I have a few more ideas.

 

The cross sectional area of a 65mm TB is a lot smaller than the cross sectional area of the plenum. So the air has high velocity going through the TB, but as soon as it goes into the plenum, velocity slows down.

Going to a smaller plenum cross sectional area will keep velocity up, but may sacrifice equal flow across the 4 runners.