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My inlet manifold project

Discussion in 'A3/S3 Forum (8L Chassis)' started by Andrew@A.L.D, Oct 2, 2011.

  1. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    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

    [​IMG]
     
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  3. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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    Such a tease... :thumbsup:

    <tuffty/>
     
  4. AARON77

    AARON77 Well-Known Member

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    Good work keep the pics coming dude
     
  5. DaveA3

    DaveA3 Audi A-Trizzle!

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    bloody hell
     
  6. jojo

    jojo Looking for Boost!
    Staff Member Moderator Team Daytona quattro Audi S3 Audi A6 Audi Avant Owner Group

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    Trying to improve the engine sound? lol
     
  7. badger5

    badger5 www.badger5.co.uk
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    shame the injector ports wreck airflow in those runners
     
  8. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    I will be looking into that
     
  9. MUSH

    MUSH MUSH Developments Ltd.

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    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
     
  10. Dani_B19

    Dani_B19 Audi-sports own special child.

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    So how do you go about altering the injector ports on the standard runners then? Is it even possible?
     
  11. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    Cut, Weld, Port, Modify... simples
     
  12. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Coolio.

    You making and selling anymore of these or this just going tobe a one off?
     
  13. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  14. Dani_B19

    Dani_B19 Audi-sports own special child.

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    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?
     
  15. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  16. Dani_B19

    Dani_B19 Audi-sports own special child.

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    :).
     
  17. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    Dropped off the inlet at the welders today

    here are a few more pics

    Machined up a base plate for the plenum

    [​IMG]

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

    [​IMG]

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

    [​IMG]
     
  18. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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

    <tuffty/>
     
  19. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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  20. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    Thats the one

    They are getting some good results over in the US with them and the AEB runners
     
  21. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Likely alot :).
     
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  23. Welly

    Welly VX220 SC Driver :)

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    Yeah man, I like the looks of this, will be interested to see the final product :)
     
  24. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    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
     
  25. MUSH

    MUSH MUSH Developments Ltd.

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    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. :)
     
  26. Westy

    Westy Well-Known Member

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    Liking the effort. Something new and exciting in the 8L section.
     
  27. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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    I suspect he will blend them in knowing his porting skillage :)

    <tuffty/>
     
  28. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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    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...

    [​IMG]

    <tuffty/>
     
  29. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    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
     
  30. MUSH

    MUSH MUSH Developments Ltd.

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

    One step at a time though....
     
  31. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    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

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    When its all done it will be painted in crackle black to match the rest of the engine bay and cam cover
     
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  32. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Sweet.

    Did you measure it with a phenolic gasket in place or just a normal one?
     
  33. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  34. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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

    <tuffty/>
     
  35. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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    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/>
     
  36. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    #34 Andrew@A.L.D, Nov 28, 2011
    Last edited: Nov 28, 2011
  37. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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  38. Dani_B19

    Dani_B19 Audi-sports own special child.

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    Would you be able to fit a phenolic gasket or would it be too tight of a fit?
     
  39. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    can't see it been a problem with the phenolic gasket?
     
  40. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    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?
     
  41. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow...
    Staff Member Moderator Audi S3

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    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/>
     
  42. Andrew@A.L.D

    Andrew@A.L.D May add NOS to 600+bhp S3.

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    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

    [​IMG]

    [​IMG]
     

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