Have you made an intake?

[Henson]

So has anyone here made their own intake? I’m thinking at least by next year, starting on an intake project. I have a few things to complete first then I may have sometime. This is what I plan…

I want to do a SS intake with a 3/8” flange. Unsure the runner size and length. At first I would like to design one for a SVO style head then later design one for an ARCA head. I’m unsure about injector bungs. Can you get those somewhere or will I have to machine them? I’m going to block the water passage as spoke about on TF. Is there anything else I’m missing? Any inputs?

I plan to use an engineering design software to figure the size and length of the runners before finalizing. Though what is your input on this?

I’m still in the researching and thinking process!

Post pic's if you have them.

Thanks.

[MacGyver]

i am curious why you would want to make it out of SS instead of aluminum?

[Raven855]

Try here for some parts: http://www.rossmachineracing.com/products.html I have not done anything w/ this head. I am doing some stuff w/ a Volvo conversion. Aluminum or carbonfiber is what I have been fooling around with.

[Pat_in_L.A.]

Another place to shop:

http://kinsler.com/

Raven, this tool on the site you mentioned looks promising:

http://www.rossmachineracing.com/injectortool.html

I imagine however, that someone with tool room/ grinding experience can make the same tool out of a real end mill rather than a drill bit.

[Raven855]

Pat, interesting web site. How about we go in half and half on the tool and keep it at my house?
Henson, I would like to hear your motivation for wanting to change. What sw were you thinking about using? I never liked what I tried. You can also find several sites out there on DIY designs.

[Pat_in_L.A.]

Pat, interesting web site. How about we go in half and half on the tool and keep it at my house?

Tony, a few guys that we know here on the board would look at that tool and immediately think "I can do better then that". There's a reason that the length of unfinished billet is only $12 but a finished fuel rail is 10x that amount. The easy way out is to just drill them vertically for a custom manifold. Our injectors however, are set at angles and not at a uniform measurement. All of a sudden a $125 fuel rail looks like a deal compared with a $129 resharpened drill bit.

I'm not trying to shoot down the ideas at all. I'm just inviting the qualified machinists to consider contributing to this thread.

[Alex L]

thirdly for AL over SS.

designing a lower intake/fuel rail for the stock head looks to be a major PITA due to the non uniform intake angles. Since the lower intake matches the crappy head flow, it seems (to me) the best return on invested time would be a simple properly sized box upper plenum, with an 'optional' set of velocity stacks leading into the lower runners. You can always make more boost.

save your energy for an ARCA intake, were you can get some real flow.

[Raven855]

Pat I understand what you are saying. And I agree with Alex L on the design of the lower intake and to just fool around with the upper. I have tried the drill bit approach and drilling the fuel rail is not near as complicated as drilling the lower intake for a shot down the throat and at the back of the valve! I have been fooling around with a lower intake for a DOHC and its even more maddening. But I have had alot of fun w/ that project so far. I have learned alot about trying to design a port for swirl instead of tumble. How the intrance to the runner can affect flow by up to 8% or even negatively. Looking at runner shape and length. Plenum design for sonic flow, reversion and hemholtz waves. How materials are affected by heat soak and even how the same material in different thickness is affected by sound and heat. I just like to see different things tried. I'll stop now.

[Pat_in_L.A.]

I'll stop now.

Don't stop now. I had no intention of stepping on your hemholtz!

[Raven855]

Henson, here is what you need to do. Get some tubing, same size as your intake ports or there abouts. The volume of the runner needs to be about 100% of what the cylinder displaces. The plenum is usually about 100% of the engine displacement. I will bring the beer, cubans and lawn chairs. If you need any porting done, we can invite gator. I understand he is good and fast like a "beaver in a wood pile". We'll invite LA Pat and we will give you moral support while you put this thing together. After a couple of beers we will get Pat to whip us up a fuel rail. WHALA, ONE CUSTOM INTAKE. Of course after we iron out the bugs on yours, we can do mine! My hemholtz will be JUST FINE!

[Henson]

Why Stainless steel? Have you TIG’d aluminum?

All very nice sites. I’m glad I started the thread now. We just finished the header project. I’ll CAD it up just as shown on the following site. Building it, even the stock style, I don’t think will be as bad as you guys think. Especially after seeing the previous tool sites.

The ECT and coolant lines are already figured out on TF. There are a few options talked about there.

Preparation is the key. Design it completely and order the tube and bungs. Less than two days it’ll be all welded.

As far as the size and length I’ll use the software for that.

http://www.gt40s.com/forum/tech-engines-induction/19431-mkii-headers-my-2006-summer-project.html

[Henson]

How/where do you plan to mount an ECT? It need flowing coolant. Besides the amount of heat (temperature, actually) transferred to the incoming air charge is insignificant from the coolant exiting the center of the manifold. But it sure does make it nice for heater bypass and shortening the oil warm-up cycle for a street car (that coolant path includes the oil heat exchanger). Oh yeah - race engines need to warm up too.

Isn't that what the turbo is for?

I might put a bung there as well. Unsure if I'll use the water oil cooler. Shouldn't the ECT be located close to the thermostat housing anyway? Didn't Ford change this in the later years? I'm told that the later years the water passage was in fact blocked off. And it was just a convent location to connect to the oil cooler. Thoughts.

[Raven855]

I see why you are thinking about the stainless. My tools and talents are different. I have a torch and mig and my welding skills are self taught, but I don't think they are very good yet. I use the "sand bending method" for my custom tubing. I am going to be using CF, carbon fiber is lighter, stronger, and has a heat transfer coefficient that is 50 times lower than that of steel, which is still 50X less than aluminum. Look here for some good info on exhausts and intakes even though its for a Harley.http://www.rbracing-rsr.com/exhausttech.htm. Nice pics of exhausts too! Look down in the calculations at the bottom, I like the one on the mach index. I also like aluminum and CF for designing the ram pipes over steel. Here is some dated info on ram pipes, bell mouths, what ever you want to call them. It would take me forever to do a bellmouth in steel, but I could do one in aluminum. The current formula for determining the entrance to the runner entrance is the radius at the end of the pipe times 2 1/2 to determine the radius leading into the pipe and extending it to about 100 degrees, if that makes sense. The other item is that cylinder filling is enhanced about 9%-12% with a pipe that decreases in size over a pipe w/ a constant radius. It would take ME forever w/ steel.

[1HOT4OT]

Here are a few intakes.The first one has two injectors per runner,tapered runners,with bell mouths,nitrous fogger nozzle bungs and burst panels for that nitrous back fire.The second is a esslinger 2 barrel deal with a fabed up plenum,was never complete.Both are for a svo or arca head.

See next post for pics.

Tim

[1HOT4OT]

I dont know what happened to the pics so here they are again.

Tim