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Engine, Exhaust, Transmission Discuss the FR-S | 86 | BRZ engine, exhaust and drivetrain. |
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07-30-2015, 11:02 AM | #1 |
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Project BRZ Intake Manifold Development
Last night a member from the So Flo BRZ/FR-S group came by and left me with a beautiful little present:
He showed me his ideas for what he wanted to achieve in creating a new intake manifold, but lacks the CAD skills to create it. So I have partnered up with him to develop the CAD side of the manifold - while he is skilled in MasterCAM and thus will be running the 5-axis CNC machines to cut the flanges and manifold base. Right now we are shooting for an equal-length runner design with a single massive collector just behind the throttle body where they split. As the design comes along I'll post some updates for everyone. Right now we are only planning to build 2 of these (1 for my car and 1 for his), but we'll see how things go and what our finished costs are.
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07-30-2015, 12:45 PM | #2 | |
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07-30-2015, 01:14 PM | #3 |
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Thanks, but I use the terminology supplied by the manufacturer and although the word plenum is used in other countries, it's nowhere to be found on the manufacturer's specifications:
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07-30-2015, 01:31 PM | #4 |
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Interesting,
You do know there are several companies in the US with the Fuji Heavy complete car in CAD you can dismantle each individual component. I can name 4 off the top of my head. Unfortunately they will not relinquish the info, I wonder how to obtain these CAD files.
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07-30-2015, 01:42 PM | #5 |
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07-30-2015, 03:15 PM | #6 | ||
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I wasn't talking about the whole intake manifold, I was talking about the collector, that why that word is in bold in my quoted text. |
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07-30-2015, 04:58 PM | #7 | |
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07-30-2015, 06:26 PM | #8 |
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Part 1 - The Flange
Here is my rough sketch of the flange built off the stock manifold. I have a few more finishing touches to add (fillets mainly) but other than that it's nearly ready to create a prototype on my 3D printer to test fitment.
Next step is the injector ports and runner adapter for the flange.
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07-30-2015, 11:33 PM | #9 |
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Flange Complete
Here is the completed flange that has had some factory areas modified for easier machining. I'll be 3D printing off a sample of this soon to line up with the stock manifold to make sure everything is perfect before proceeding to the next step.
After that I will build the injector ports with the adapter flange that converts the oval into a 2.5" circle so we can weld on some custom mandrel bent tubing to the collector.
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08-03-2015, 12:20 PM | #10 | |
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The flange is easy I have had that done for 2 years now. Additionally to save costs I have a gasket made in a flat design to avoid the additional cost of CNC for the rubber Oring> Difficult part is Port injector placement, and angle then loft the oval to round.
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08-03-2015, 12:23 PM | #11 | |
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By the end of the week I hope to have the injector part completed so I can move on to the throttle body plate. I already printed off one copy of the flange which fits perfect. It will use the stock rubber gaskets.
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08-03-2015, 12:34 PM | #12 | |
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08-03-2015, 03:39 PM | #13 |
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Yes, minor differences. The ports are about 3mm moved in one direction on one side compared to the other, and one of the mounting holes is about 10mm down and 7mm over (roughly).
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08-03-2015, 06:26 PM | #14 |
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Sorry, I don't know what it is that is being designed here.
Am I correct this is going to be a tuned length intake mimicking free to air trumpets? That is, another interpretation of the Velox manifold? *starts fantasizing about another 10 na hp*
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