My inlet manifold project

[Andrew@A.L.D]

Take one AEB inlet, Cut off the plenum, Order a universal plenum from the US, Get some trumpets from Jenvey, Make up a jig for bosses that hold the S3 engine cover on.

I'm about to machine the base plate to match the ports then i got to get it welded up

More pics to come

 

[<tuffty/>]

Such a tease... :thumbsup:

<tuffty/>

 

[AARON77]

Take one AEB inlet, Cut off the plenum, Order a universal plenum from the US, Get some trumpets from Jenvey, Make up a jig for bosses that hold the S3 engine cover on.

I'm about to machine the base plate to match the ports then i got to get it welded up

More pics to come

Good work keep the pics coming dude

 

[DaveA3]

****** hell

 

[jojo]

Trying to improve the engine sound? lol

 

[badger5]

shame the injector ports wreck airflow in those runners

 

[Andrew@A.L.D]

shame the injector ports wreck airflow in those runners

I will be looking into that

 

[MUSH]

shame the injector ports wreck airflow in those runners

Thats why i chose to build mine from scratch, using the RMR injector ports which will be flush with the inside of the runners. Done well youll still get a cracking manifold though, gota be better than the standard smallport

 

[Dani_B19]

So how do you go about altering the injector ports on the standard runners then? Is it even possible?

 

[Andrew@A.L.D]

So how do you go about altering the injector ports on the standard runners then? Is it even possible?

Cut, Weld, Port, Modify... simples

 

[Dani_B19]

Coolio.

You making and selling anymore of these or this just going tobe a one off?

 

[Andrew@A.L.D]

yes i will if people want them?

 

[Dani_B19]

Im up for 1 mate, like mush said, anything is better than the smallport manis thats on at the minute.

Any rough ideas on the price theyd go for?

 

[Andrew@A.L.D]

I'll let you know when done

 

[Dani_B19]

.

 

[Andrew@A.L.D]

Dropped off the inlet at the welders today

here are a few more pics

Machined up a base plate for the plenum

I also had to turn down the trumpets/stacks to make it easier to weld up and to fit the plenum.

Had to make a jig for the mounting bosses for the engine cover

 

[<tuffty/>]

Good work mate... I have seen that plenum before... looks familiar anyway... got a link?

<tuffty/>

 

[<tuffty/>]

Think I have found it

Online Store - Xcessive Manufacturing

<tuffty/>

 

[Andrew@A.L.D]

Thats the one

They are getting some good results over in the US with them and the AEB runners

 

[Dani_B19]

Likely alot .

 

[Welly]

Yeah man, I like the looks of this, will be interested to see the final product

 

[Andrew@A.L.D]

I will be posting more pics today

I will need to blend the welds in on the trumpets/stacks when i pick it up and then get the plenum welded on

 

[MUSH]

Looks good but wouldnt it be better if the trumpets were flush with the base plate to give a mega smooth transition?

Like that youve made a jig so your engine cover goes back on.

 

[Westy]

Liking the effort. Something new and exciting in the 8L section.

 

[<tuffty/>]

Looks good but wouldnt it be better if the trumpets were flush with the base plate to give a mega smooth transition?

Like that youve made a jig so your engine cover goes back on.

I suspect he will blend them in knowing his porting skillage

<tuffty/>

 

[<tuffty/>]

Kinda like the idea of this... be interesting to see final fitment as the plenum looks bigger than the SEM and that can be tight... assuming you haven't measured already (I am guessing you have but this is for the benefit of others...) it would be worth tacking the runners and back plate on and offering up first to make sure there are no clearance issues...

The SEM is a tight fit but the runners are quite long lifting it quite high to give clearance for the alternator...

<tuffty/>

 

[Andrew@A.L.D]

Looks good but wouldnt it be better if the trumpets were flush with the base plate to give a mega smooth transition?

Like that youve made a jig so your engine cover goes back on.

Its been welded on the inside of the trumpets and then ported smooth

i did do some measurements and it should fit ok

Its just a tad bigger than the SEM

 

[MUSH]

Making me want to break My manifold bits out and get to work!!

One step at a time though....

 

[Andrew@A.L.D]

Here are a few more pictures

Also some pictures of a plenum i was going to use but i'm now using it for another project for a friend

When its all done it will be painted in crackle black to match the rest of the engine bay and cam cover

 

[Dani_B19]

Sweet.

Did you measure it with a phenolic gasket in place or just a normal one?

 

[Andrew@A.L.D]

Just a normal gasket

 

[<tuffty/>]

Looks really good mate... hummm... really thinking I could be tempted to do this...

<tuffty/>

 

[<tuffty/>]

Be interesting to see if a plenum that size introduces a little more lag...

Be good to see a back to back of a std mani vs that one...

<tuffty/>

 

[Andrew@A.L.D]

http://www.80tq.com/~wiz/gallery2/d/1116-1/Intake+Manifold+Comparison.PNG

As you can see the Homebrew (AEB lower + Ross machining D plenum) seams to do well with flow

A dam site better then a standard small port that i had on

This is a better plenum so should so a little better i hope

 

[Andrew@A.L.D]

Some logs from someone on vortex.com

VWVortex.com - Xcessive intake manifold impressions w/ logs

 

[Dani_B19]

Would you be able to fit a phenolic gasket or would it be too tight of a fit?

 

[Andrew@A.L.D]

can't see it been a problem with the phenolic gasket?

 

[Andrew@A.L.D]

Be interesting to see if a plenum that size introduces a little more lag...

Be good to see a back to back of a std mani vs that one...

<tuffty/>

Lag isn't that bad with my engine as it is

When my car is all done i would be willing to come down and see you and Bill so you can borrow it for back to back testing on your dyno?

 

[<tuffty/>]

Lag isn't that bad with my engine as it is

When my car is all done i would be willing to come down and see you and Bill so you can borrow it for back to back testing on your dyno?

Sounds like a plan... hoping to get mine sorted in the next few weeks and hopefully mapped at some point over christmas if all oes well

<tuffty/>

 

[Andrew@A.L.D]

All done and dusted

Did a test fit to the engine and its tight next to the alternator but all is well, even the engine cover fits nicely

i didn't leave it on as i want to paint it