finally started on custom intake manifold project

[sTTanford]

after months of talking the talk, i finally had a few hours to put into the project tonight. The goal of this project is to create a custom intake manifold, cast out of aluminum (6061, 5052, we'll see). the main desired features are secondary injector bungs (and mounts for the secondary fuelrail) as well as a larger plenum.

With all the R&D effort required, it would be a shame to make this a one-off manifold, so after polling interest over on more custom-work-oriented forums (vortex), i'm planning on making a handful of these to custom order. to accomodate my R&D needs (and other ppl's requests), i plan on making it modular, so the user can combine a certain port size and runner length with a plenum. no, this is not an ad: i'm not taking orders.

first step first: gasket matching. should be able to get it bang on after an iteration or two. making sure i have the right dimensions for the ports and manifold profile is pretty important, especially where it mounts to the head.


SolidWorks model


my old ATC (180TT) intake manifold. I compared it to the AMU (225TT) manifold the other day, and the ATC mani has a slightly smaller plenum, visibly noticeable though.

you can see the paper cut-outs i was using the check my dimensioning. i'll have a 0.250" acrylic piece lasercut tomorrow to double check everything, mount holes, ports, etc.

[Lightweight-USPowah]

[sTTanford]

use the existing injectors as triggers, and have a PIC microprocessor that decides on a dutycycle.

i could have it open-loop, meaning it just does a length adjustment. eg, if the ECU requests a 50% DC for the primaries, the secondaries inject at 20%, ECU does 60%, secondary does 30%, etc. That is a predictable and easy calculation.

I could have more of an ECU-style look-up table that can be be one dimensional (boost), two dimension (boost, RPM), three dimension (boost, RPM, speed), etc, which still would use the primary injectors as a trigger.

[Ballin00TTq]

I am planning on upgrading the turbo but wasnt thinking of doing secondarys..

U might convince me to go secondarys like billy, but I still dont understand what your gonna use to control them!!

[Lightweight-USPowah]

would go with a stand alone.. : / With the forge program coming out though.. wow that itself seems like a standalone.. There are reports that it allows you to control everything.. so phatt..