Thread: NEW JBS IHI Cast and Tubular Manifolds

IHI stage 1 Cast Manifold


The JBS development team has been working on a new cast K03 performance manifold, alongside this we have been working on a new GT28, Twin Scroll and the IHI stage one manifolds, which are also to be cast and will run alongside the new JBS tubular designs.


JBS will produce the tubular manifold, but due to a drop in manufacturing quality the new IHI tubular design will be produced in house. The new designs concentrate more on collector efficiency and eliminating port sharing.


Once the process of designing a cast K03 manifold started it became a lot easier to produce cast manifolds to suit other turbos. Having the new manifolds cast gives better quality to mass production and gives fewer constraints on the pipe bend radiuses, collector design and also allowing the runners to flow freely. Making the new JBS designs far superior to the competition.


The manifold has been designed in CAD to optimise the collector, flow capabilities and to enable easier fitment. The CAD process allows the designers at JBS to manipulate the part quickly and while allowing information and measurements to be taken easily, which would be physically impossible to do by hand.





The new JBS manifold design runs through the range of new cast and tubular manifolds, with the runners and collector being specially designed for the casting process to give the greatest flow.






The new design flows the combustion gasses through a close to 90 degree angle in the runner before they enter the collector. Changing the direction of the flow in such a way gives better directional flow of the gas into the turbine, as well as defeating port sharing. Port sharing occurs on many of the flat manifold designs produced by other companies.

The cylinder head flange has been redesigned to allow greater thermal expansion and movement between the runners. The designers found that a too restrictive flange forced stresses back through the runners of the manifold which lead to crack propagation.


Once we were happy with our design it was sent off for rapid prototyping to give us a physical model to evaluate before any design finalisation can take place. The rapid prototype is a highly accurate model taken straight from the CAD data.









JBS has chosen to cast its manifolds in a very high quality UK based foundry which is used by the likes of Borg Warner and many other OEM turbo suppliers to ensure the castings are of the highest quality. To reflect the high quality casting, we have chosen the same material as the hot side of the turbochargers D5S ni-Resist is a cast irons with high nickel content has the following properties: resistance to corrosion, resistance to oxidisation and high temperatures, resistance to wear and erosion. This is to ensure a minimal amount of thermal expansion and an equal rate of thermal expansion to the turbo housing, this again minimises the potential for thermal fatigue.


Once the first batch of manifolds are produced, they shall be thoroughly tested and dynode. At which time all power and flow figures will be released. Once all testing is completed and we are happy with the results we aim to release the manifolds at £420 including VAT.

We also have a K03 cast manifold going into production with the new IHI and GT28 stage one manifolds. As well as having K04 and Twin Scroll manifolds going through our design process and rigorous testing and hope to be able to bring them to you as soon as possible.

JBS IHI stage 1 Cast manifold

Once we were happy with our design it was sent off for rapid prototyping to give us a physical model to evaluate before any design finalisation can take place. The rapid prototype is a highly accurate model taken straight from the CAD model data.

This first prototype was produced so we could test the IHI and Garrett turbo fitments, as well as evaluating the base model for casting. When the manifolds go into production they will be individually machined into one fitment.

· 1.8T IHI
· 1.8T Garrett T2
· And now 2.0 TFSI fitment for both IHI and Garrett.




(The cast multiple turbo flange will be machined into IHI and Garrett T2 fitment)

The rapid prototype gives a huge advantage in being able to fit the manifold to an engine and turbo, to test and ensure that the product achieves its specification.

The IHI stage 1 manifold has been designed to fit a IHI VF34 & VF22 and Mitsubishi 16G & 18G to the 1.8T engine, more turbo options will be available after test fitting.


(Kit s shown is the for Mk3 seat Ibiza stage 1 )




(Runners spacing designed to help ease of fitting)

The IHI stage 1 manifold is also being developed for the 2.0 TFSI, which offers a wider range of turbo fitments.
We are also able to physically flow test our design and compare it to our CFD (computational fluid dynamics) data before being sent for casting.



Being able to flow test our rapid prototypes has helped us to develop the manifold to flow considerable better than previous models and others on the market. This is due to the complex design and hours spent on CFD for individual runners, giving the exhaust gas better flow and balance throughout the runners.

Once the first batch of manifolds is produced, they shall be thoroughly tested and dyno’d. At which time all power and flow figures will be released. JBS will release the new manifold once all testing is completed and we are happy with the results.

JBS developments has also been working on a cast down pipe for the IHI stage one turbo kit.



The downpipe is designed to separate the turbo exhaust out flow and the wastegate flow to remove turbulents in the downpipe.

The difference with the JBS designed downpipe compared to other manufactures is that the exhaust and wastegate flow are kept seperated deeper into the downpipe to improve gas flow.

(The wastegate and exhaust gas are split for ¾ of the length of the downpipe)

It also has cast in mounting points for the lambda and EGT sensors if they are required.



(The downpipe can be machined to fit the different depths of IHI and Mitsubishi exhaust turbine housings)


(Lambda probe fitted)

The downpipe flange will fit all types of IHI/Mitsubishi turbos, allowing for different size turbo exhaust gas outlets and flange depths.



(To the right of the exhaust gas port you can see that the cast turbo flange will separate the exhaust and wastegate flow as soon as it leaves the turbine housing and is a perfect fit)



The downpipe will be cast from the same ni-resist cast iron (D5S) as the manifold and hot side of the turbo. This is to ensure a minimal amount of thermal expansion and an equal rate of thermal expansion through the manifold, turbo housing and down pipe, this minimises the potential for thermal fatigue.


(IHI VF34 exhaust housing fitted with stage 1 manifold and downpipe)


The downpipe shall be released shortly after the manifolds. The downpipe and manifold will be available as part of the JBS IHI stage 1 turbo kit as well as individually.

The downpipe and manifold will be thoroughly tested together and dyno’d. At which time all power and flow figures will be released.

as usual nicely made and very well thought out! why have you gone back to the log style underslung manifold or have i missed somethingi thought the equal length one was the only way to go according to you?
steve

Originally Posted by steve-tt

as usual nicely made and very well thought out! why have you gone back to the log style underslung manifold or have i missed somethingi thought the equal length one was the only way to go according to you?
steve

Hi Steve,

Thanks for your comment.

JBS will still be producing equal length manifolds.

As with all our new design stage 1 tubular manifolds and cast designs the runners have been designed to optimise the collector design to increase flow.
The new designs are based around OEM fitment to make best use of all the standard positioning of boost hoses, downpipes etc

We currently have in development a new equal length stage 2 manifold.


JBS Developments

Guys,

I have one of your stage 1 welded IHI setups. Are the dimentions and fitting locations the same with the new split downturn the same as the old welded item? Could I simply swap mine out for this new one?

What is the estimated cost for one machined to fit a TD05 housing with provision for an exhaust temp sensor?

Hello,

The manifold should be a direct replacement for you as flanges were set to be in the same location.

The new cast version is set to fit 16G/18G and VF34 turbocharges.

Expected cost of the manifold is to be £380inc VAT but this may change.

As for the temp sensor, I am sure we could arrange this but I am not sure of costing at this moment in time.

Regards
Mike

Mike,

I don't want a new manifold, mine is fine.

I'm after just the downpipe top section with the separated flow. Are the bolt locations the same as the old welded kit and can I just fit that part?

So : Original stainless manifold --> new cast downpipe top section (with EGT hole) --> old stainless downpipe.

Also, a price for the downpipe top section.

Thanks.

Sorry, read your post asking for a manifold for some reason!

The downpipe turn is going to be made but we are just pending a sample of this from our caster.

Pricing on the downpipe turn is currently pending but when we get the sample I will have a better idea then.

Mike

No probs. I wasn't very clear. I'll wait in the wings for production.