Looking to find the intake mani flange that goes to the cylinder head..I know i can find the exhaust flange, but dont know if there is any place that makes the intake side, or am I going to have to have one CNC'd for me..Thanks for any info.

my guess is CNC'd. making custom intake manifolds isnt quite as popular a venture for the average person as say...a custom exhaust manifold.

Considering the stocker is cast, I bet you're going to want CNC, sir.

I smell a project a brewing!

Originally posted by Chamuko
I smell a project a brewing!

I agree, what you working up? I was actually just thinking of this idea the other day if I got a welder. Maybe just welding up random intake manifold designs and trying them out, just to dick around. But I think flanges would be hard to find.

Yeah i've been wanting to make up an intake manifold for the longest time, and my "winter project" this year will be an intake and exhaust manifold. The exhaust mani i'm not concerned about, i have a good idea how to do that and i know where to get the flange. I'm really wanting a steel intake flange, so i can weld it up with my MIG. Our stock intake mani sucks ass for boost..I'm almost positive there are at least one or two cylinders that get more air than the others under boost. I've even thought about using the Port Fueler spacer plate as a flange, but its aluminum, and to help keep this under budget, its gotta be steel. Hmm maybe i could use that for the injection portion, and then bolt up a custom mani to that plate. May simplify the design.

Originally posted by XtremeRS
Hmm maybe i could use that for the injection portion, and then bolt up a custom mani to that plate. May simplify the design.

That might be a good idea. Then again, you could take a stocker, cut off the flange, then use countersunk bolts to mate it to your runners. Just an idea, but I like hearing about people looking in new directions.

Yeah, I have been toying with a design in my head kind of like a reverse design of our 4-1 headers. Like have a collector type design right after the tb with the 4 runners facing the throttle body and coming off to the head flange. It seems like it would give great air distribution and great intake velocity. But thats only what my guess would be, I would have to try it.

Originally posted by GSGoinFast
Yeah, I have been toying with a design in my head kind of like a reverse design of our 4-1 headers. Like have a collector type design right after the tb with the 4 runners facing the throttle body and coming off to the head flange. It seems like it would give great air distribution and great intake velocity. But thats only what my guess would be, I would have to try it.

In forced induction applications velocity really isnt that big of a problem.

Originally posted by greygoose

Originally posted by GSGoinFast Yeah, I have been toying with a design in my head kind of like a reverse design of our 4-1 headers. Like have a collector type design right after the tb with the 4 runners facing the throttle body and coming off to the head flange. It seems like it would give great air distribution and great intake velocity. But thats only what my guess would be, I would have to try it.

In forced induction applications velocity really isnt that big of a problem.

Well I would imagine it would flow better then our stock design

Unless you know someone who operates a mill or has access to one having it cut on water jet will be a much cheaper option for the same end result.

All you need to do is trace the intake manifold gasket on a piece of paper, scan it, import it into a CAD program (solid works, AutoCAD, etc) and trace over the lines. (Create vector based line work). Once you have a 1:1 CAD drawing you can take it, fax it or email it to shops that do water jet cutting for an estimate. Off the top of my head the guy I use here in Denver would probably charge $75-100 for .5" aluminum and cut time.

I do this same technique with my gaskets. I just converted all my gaskets into vector drawings and cut them on a laser cutter. The only downside is that the laser I use can’t cut through steel or aluminum. It cuts through about everything else though.

Brian

Even easier: you can skip 'tracing' over the 2-D scan in your favorite CAD, use a Raster to Vector program (R2V for example).

Well it turns out one of the guys I work with, his dad operates a water jet machine..So he may be able to do something for me. I even told the guy i work with, that he could make some extra money to make up a few and sell em lol..He says the machine can cut up to 1" thick steel. Sweet.

Matt,

Please let me know if you can have an aluminum flange made. I'm down for 1 or 2.

Interested in a steel flange possibly, keep us posted as to your progress.

How bout somethin like this...






My buddies new manifold he just got for his SE-R :bowdown

He got it from http://www.o2induction.com That guy is an artist for sure, that baby looks immaculate. I got him to talk to the guy for me, and he said he would do a design for us as long as there was a little bit of interest from a couple members :thumbsup

Originally posted by XMasta19
How bout somethin like this... My buddies new manifold he just got for his SE-R :bowdown He got it from http://www.o2induction.com That guy is an artist for sure, that baby looks immaculate. I got him to talk to the guy for me, and he said he would do a design for us as long as there was a little bit of interest from a couple members :thumbsup

That manifold gives me a chubby, though the goober holding it deffinately has a flacidity inducing quality.

Yeah he pisses me off everytime he gets somethin like that in the mail lol. Then I'll be like, oh yeah look I got brembos, or oh check out my megasquirt hehe.

Yeah waterjet is what I would suggest as well.
If ya want, I have some free time seeing as its summer and all. Ill try and get Soemthing made in solidworks for you guys.

I have some papers from the SAE library on intake manifolds and plenum designs, along with tumble characteristics, angles etc... I get half way through and then it gets real technical...

edit: think you mean http://www.o2induction.com/ (wow he really cuts it close with those TB's)

oh and Ive been looking at http://www.rossmachineracing.com/
I say we Start a thread in the Advanced section Pls...

edit 2: http://www.rossmachineracing.com/intakeparts.html

man those injector bungs are at a decent price...hmmm

what about using the portfueler flange as a starting point. i dont know how optimal the injector placement is or the injector angle is. but it might be worth looking into. from what i understand hahn sells all the parts alone so you should be able to buy it from them. just a thought, might be cheaper than getting one machined.

Might work... the angle is important don't get me wrong but it's not that big of a deal either, it just changes the equlibrium of how the fuel pools up on the intake tract and then evaporates again. This could probably be mostly corrected for in software. Think of wet manifolds with carbs, they work pretty well considering how far the fuel goes after it meets up with the atmosphere. The PF flange would be a good place to start from, depending on how beefy it is. I vaugely remember how thick the thing was, maybe 1/2" when I first saw it at the 04 shootout.