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   All Posts (The_Engine_Room)


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The_Engine_Room
Re: CNC A series Oval Flange
#1
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I like the design but I have no idea how you'd actually make one short of investment casting or lost wax/foam casting.

Posted on: 2016/5/26 13:34
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The_Engine_Room
Re: CNC A series Oval Flange
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Quote:

tboe0 wrote:
Damm that looks good!
LOVE your rail/holder :O what is the length between the flange and the rail?
Great design, would like to make a set of my own... are you mounting them with one long bolt through the middle? or do you screw it into to flange?


38.1mm (1-1/2"), which is strange since the injector is stock for a 2004 Honda Civic Si. It's the same length as a "GM LS2" injector.

Attach file:


jpg  IMG_20160519_065959572.jpg (174.44 KB)
18181_573d9e7766f2d.jpg 617X600 px

jpg  IMG_20160519_070005752.jpg (171.02 KB)
18181_573d9e9377043.jpg 784X556 px

Posted on: 2016/5/19 12:08
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The_Engine_Room
Re: CNC A series Oval Flange
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Those injector bosses are machined into the flange adapter. It's all one piece.

This particular manifold came from a 1995 Mercury Tracer (USA). It was rated at 92hp 100tq.

The runners are 32mm ID 38mm OD mandrel bent tubing and are about 29 cm long after I cut them off and cleaned them up. The plenum is 54mm ID 60mm OD tubing with a stamped cap on one end. The stock throttle body is ~40mm.

It's a fantastic starting point especially since I only paid $24 at a local salvage yard.

Posted on: 2016/5/17 13:23
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The_Engine_Room
Re: CNC A series Oval Flange
#4
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Here are some "renderings" of what I'm working on.

Attach file:


jpg  Mock-up Overview.jpg (180.58 KB)
18181_5739aeb7d581d.jpg 600X722 px

jpg  Fuel Rail Installed.jpg (126.87 KB)
18181_5739aebfbf22a.jpg 800X349 px

jpg  Injector Detail.jpg (170.13 KB)
18181_5739aeca2af1a.jpg 792X575 px

Posted on: 2016/5/16 12:28
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The_Engine_Room
Re: CNC A series Oval Flange
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If you used the measurements that we discussed earlier then the location should be pretty close. The first set that I made were drilled to 8.3mm and they slipped right on.

Posted on: 2016/5/11 13:30
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The_Engine_Room
Re: Intake Manifold Plates
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Well, I've had a minor disaster. I was welding the plenum and didn't notice that I picked up a stainless filler rod. I'm going to sleep on this one since the more I try to fix it, the worse it gets.

Attach file:


jpg  20160506_151705.jpg (180.69 KB)
18181_572cee7ebc3ed.jpg 792X532 px

Posted on: 2016/5/6 20:20
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The_Engine_Room
Re: Intake Manifold Plates
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Quote:

lamb_daiquiri wrote:
Very close to what I've designed! I may be interested in a set, how thick are they? I designed them to be machined from a 25mm thick bar. I'm after lowest profile possible because I want my manifold to wrap up over the rocker cover and leave all the space that side for a turbo exhaust manifold.


Take a look at an early to mid 1990s Ford Escort/ Mercury Tracer with base 1.9L SOHC engine. I was initially going to use that intake manifold as a base from which to fabricate.

http://www.ebay.com/itm/91-92-93-94-9 ... -FED-773611-/400987659985

Posted on: 2016/5/6 19:34
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The_Engine_Room
Re: Intake Manifold Plates
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The people who build aftermarket intakes live and die by the peak horsepower numbers. I can't stand peak HP engines because they suck to drive anywhere but onto a dyno. Also, shorter intake runners are easier to fabricate and they package better.

Since I'm going forced induction with a (relatively) big turbo, I'm building the intake for torque and letting the turbo take over up top. A good place to start if you are running the stock cam is to just make them the same length or a little shorter than the stock runners.

Here's another good explanation.

http://www.team-integra.net/forum/blo ... er-size-calculations.html

Posted on: 2016/5/6 19:30
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The_Engine_Room
Re: Intake Manifold Plates
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Here's what I have mocked up to check for clearances. This is not how it'll end up as the runners would be WAY too short. I'll probably throw a 90` elbow in there and put the rounded part facing up; closer to the hood.

Attach file:


jpg  100mm Runners Mock-up.jpg (184.21 KB)
18181_572b9b5976348.jpg 784X588 px

jpg  Plenty of Room.jpg (166.48 KB)
18181_572b9b614b12f.jpg 841X553 px

Posted on: 2016/5/5 20:15
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The_Engine_Room
Re: Intake Manifold Plates
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It's all set up for 1.5 x 0.065 tubing. I actually made a set of the intake flanges in both steel and aluminum.

Posted on: 2016/5/5 13:41
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