New plenum design check it out
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From: Houston, Texas, USA
New plenum design check it out
This is the plenum design I will be using for my new upcoming intake manifolds (b/d/k/f20c/f22c/h22)
-James
Modified by JG-Fabrications at 5:55 PM 3/7/2007
Modified by JG-Fabrications at 6:03 PM 3/7/2007
Re: New plenum design check it out (tony1)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 »</TD></TR><TR><TD CLASS="quote">I can't find the pics, but that looks exactly like Full Race's hand made manifolds</TD></TR></TABLE>
here we go....
here we go....
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From: Houston, Texas, USA
Re: (weiRtech)
too bad you cant really form 1/8" thick material
and 1/16" is a bit to thin to be reliable
Maybe someday I will be baller enough to get them stamped out as a stamped part has alot better finish than a cast part hell I can make the dies myself (well my old man can)
-James
Modified by JG-Fabrications at 7:52 PM 3/7/2007
and 1/16" is a bit to thin to be reliable
Maybe someday I will be baller enough to get them stamped out as a stamped part has alot better finish than a cast part hell I can make the dies myself (well my old man can)
-James
Modified by JG-Fabrications at 7:52 PM 3/7/2007
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From: Milwaukee, WI
Re: New plenum design check it out (tony1)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 »</TD></TR><TR><TD CLASS="quote">I can't find the pics, but that looks exactly like Full Race's hand made manifolds</TD></TR></TABLE>
Wait. Is that sarcasm I sense?!
Wait. Is that sarcasm I sense?!
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Joined: Mar 2006
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From: Surprise, AZ
Re: New plenum design check it out (JG-Fabrications)
wow........... thats almost the exact same style that my next intake was going to made with. except i was going taper the back wall all the way down to the plenum floor like i currently do and the plenum opening is going to be a little taller than that with a steeper angle on the ramp down to the floor with the t-body at an angle (kinda so its facing all the runner openings in the plenum floor). i like it! 
Modified by all_motor_mike at 9:33 PM 3/7/2007
Modified by all_motor_mike at 9:33 PM 3/7/2007
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Re: New plenum design check it out (all_motor_mike)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 »</TD></TR><TR><TD CLASS="quote">I can't find the pics, but that looks exactly like Full Race's hand made manifolds</TD></TR></TABLE>
here is the one Geoff built...
here is the one Geoff built...
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Joined: Feb 2005
Posts: 1,423
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From: San Diego
Re: New plenum design check it out (blues2k3)
you think a large plennum like that would work well on an na setup? i got alittle scared on going big with the one in my car so i just chopped it up a little and cleaned the inside then enlarged the plennum a little. are you going to dyno one of these on an na setup?
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Re: New plenum design check it out (.john.)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by .john. »</TD></TR><TR><TD CLASS="quote">you think a large plennum like that would work well on an na setup? i got alittle scared on going big with the one in my car so i just chopped it up a little and cleaned the inside then enlarged the plennum a little. are you going to dyno one of these on an na setup?
</TD></TR></TABLE>
Yes sir should have some dynos of it within the next month or 2 (will also have a dyno of my upcoming header for the car)
</TD></TR></TABLE>Yes sir should have some dynos of it within the next month or 2 (will also have a dyno of my upcoming header for the car)
OG Fabricator
Joined: Feb 2005
Posts: 1,864
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From: Burlington, Ont., Canada
Re: (JG-Fab.com)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by JG-Fab.com »</TD></TR><TR><TD CLASS="quote">too bad you cant really form 1/8" thick material
and 1/16" is a bit to thin to be reliable
Maybe someday I will be baller enough to get them stamped out as a stamped part has alot better finish than a cast part hell I can make the dies myself (well my old man can)
-James
Modified by JG-Fabrications at 7:52 PM 3/7/2007</TD></TR></TABLE>
now your thinking what i was thinking. i don't think it will be that long before you are that baller. 
i'll have to dig up some pics i saw of a formed plenum.
and 1/16" is a bit to thin to be reliable
Maybe someday I will be baller enough to get them stamped out as a stamped part has alot better finish than a cast part hell I can make the dies myself (well my old man can)
-James
Modified by JG-Fabrications at 7:52 PM 3/7/2007</TD></TR></TABLE>
now your thinking what i was thinking.
i don't think it will be that long before you are that baller. i'll have to dig up some pics i saw of a formed plenum.
Joined: Oct 2004
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From: Brampton, On, Canada
Re: (weiRtech)
maybe this
Here is a flow test on a bunch of intake manifolds that are available for the VW 20V.
http://www.elitedubs.com/index....html
OG Fabricator
Joined: Feb 2005
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From: Burlington, Ont., Canada
Re: (monster007)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by monster007 »</TD></TR><TR><TD CLASS="quote"> Here is a flow test on a bunch of intake manifolds that are available for the VW 20V.
http://www.elitedubs.com/index....html
</TD></TR></TABLE>
results speak volumes.
http://www.elitedubs.com/index....html
</TD></TR></TABLE>results speak volumes.
FSAE
Joined: Jan 2002
Posts: 5,495
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From: Drinking Beer, UT
Re: New plenum design check it out (Cole D)
Get a hold of some good CFD software like STAR-CD, that will help you shape the plenum for equal distribution, and can allow you to do simulated flow benching.
I've been doing a lot of CFD work with plenum volume, runner length, and plenum shape over the last three weeks on our Formula-SAE motor. A tapered cone with protruding trumpets seem to have the best air velocity.
Generally, you design the plenum via CFD and choose runner length and size by using alternate Helmholtz Resonance methods.
Good luck
I've been doing a lot of CFD work with plenum volume, runner length, and plenum shape over the last three weeks on our Formula-SAE motor. A tapered cone with protruding trumpets seem to have the best air velocity.
Generally, you design the plenum via CFD and choose runner length and size by using alternate Helmholtz Resonance methods.
Good luck
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Re: New plenum design check it out (92TypeR)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 92TypeR »</TD></TR><TR><TD CLASS="quote">Get a hold of some good CFD software like STAR-CD, that will help you shape the plenum for equal distribution, and can allow you to do simulated flow benching.
I've been doing a lot of CFD work with plenum volume, runner length, and plenum shape over the last three weeks on our Formula-SAE motor. A tapered cone with protruding trumpets seem to have the best air velocity.
Generally, you design the plenum via CFD and choose runner length and size by using alternate Helmholtz Resonance methods.
Good luck </TD></TR></TABLE>
Are you simulating the actual valve opening events?
I've been doing a lot of CFD work with plenum volume, runner length, and plenum shape over the last three weeks on our Formula-SAE motor. A tapered cone with protruding trumpets seem to have the best air velocity.
Generally, you design the plenum via CFD and choose runner length and size by using alternate Helmholtz Resonance methods.
Good luck
</TD></TR></TABLE>Are you simulating the actual valve opening events?
FSAE
Joined: Jan 2002
Posts: 5,495
Likes: 1
From: Drinking Beer, UT
Re: New plenum design check it out (99_GS-T)
Yes, if you need to get very intracate in terms of exacting runner length, plenum volume and shape, STAR is capable of simulating the dynamics of the engine.
However, even with just port entry angle, size, throat dia, and valve size with approx engine HP/TQ and target peak RPM's, you can get within 90% accuracy. And when you are dealing with a part that could potentially go into production for various setups, you do not need to be that exact.
However, even with just port entry angle, size, throat dia, and valve size with approx engine HP/TQ and target peak RPM's, you can get within 90% accuracy. And when you are dealing with a part that could potentially go into production for various setups, you do not need to be that exact.
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Re: New plenum design check it out (92TypeR)
A teaser pics of things to come
That is twin injectors and direct port no2 boss all crammed in there
Custom fuel rail will be made to match the injector angles
This is just preliminary design alot more has to be done before it is ready to be cut
Will be fully modular intake manifolds
-James
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Re: New plenum design check it out (dturbocivic)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by dturbocivic »</TD></TR><TR><TD CLASS="quote">is this for your s2k build ?</TD></TR></TABLE>
I was going to use my old thing until I had a guy order a custom s2k intake manifold with direct port no2 fittings, twin injectors, and wanted everything modular (well I threw that in for free)
Basically he is paying for our time to develop a very bad @$$ intake manifold and it is much more bad @$$ than mine so I am going to have to run one on mine too
Will have 2 different plenum versions
Turbo Street/All motor (formed 3.5" plenum a little more volume than a eldebrock with a near perfect air distribution good to 80mm tb)
Pro Turbo (formed 4" plenum good to 100mm Throttle, much larger plenum than the street vs with near perfect air distribution)
The only thing that will be welded on the entire manifold is the plenum after that it is very modular similar to the hyper tune.
The runners/primaries/w/e you want to call them will be sealed with o-rings
There will be lefthand/righthand studs that we custom make that holds the plenum to the head flange (you only have 3 bolts to undo to disassemble the entire thing)
-James
Modified by JG-Fab.com at 3:28 PM 3/17/2007
I was going to use my old thing until I had a guy order a custom s2k intake manifold with direct port no2 fittings, twin injectors, and wanted everything modular (well I threw that in for free
)Basically he is paying for our time to develop a very bad @$$ intake manifold and it is much more bad @$$ than mine so I am going to have to run one on mine too
Will have 2 different plenum versions
Turbo Street/All motor (formed 3.5" plenum a little more volume than a eldebrock with a near perfect air distribution good to 80mm tb)
Pro Turbo (formed 4" plenum good to 100mm Throttle, much larger plenum than the street vs with near perfect air distribution)
The only thing that will be welded on the entire manifold is the plenum after that it is very modular similar to the hyper tune.
The runners/primaries/w/e you want to call them will be sealed with o-rings
There will be lefthand/righthand studs that we custom make that holds the plenum to the head flange (you only have 3 bolts to undo to disassemble the entire thing)
-James
Modified by JG-Fab.com at 3:28 PM 3/17/2007
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From: BeLlInGhAm, Wa
Re: New plenum design check it out (JG-Fab.com)
<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by JG-Fab.com »</TD></TR><TR><TD CLASS="quote">
I was going to use my old thing until I had a guy order a custom s2k intake manifold with direct port no2 fittings, twin injectors, and wanted everything modular (well I threw that in for free)
Basically he is paying for our time to develop a very bad @$$ intake manifold and it is much more bad @$$ than mine so I am going to have to run one on mine too
Will have 2 different plenum versions
Turbo Street/All motor (formed 3.5" plenum a little more volume than a eldebrock with a near perfect air distribution good to 80mm tb)
Pro Turbo (formed 4" plenum good to 100mm Throttle, much larger plenum than the street vs with near perfect air distribution)
The only thing that will be welded on the entire manifold is the plenum after that it is very modular similar to the hyper tune.
The runners/primaries/w/e you want to call them will be sealed with o-rings
There will be lefthand/righthand studs that we custom make that holds the plenum to the head flange (you only have 3 bolts to undo to disassemble the entire thing)
-James
Modified by JG-Fab.com at 3:28 PM 3/17/2007</TD></TR></TABLE>
awesome! This will be great for the peeps who want to make big power on E85 :-D
I was going to use my old thing until I had a guy order a custom s2k intake manifold with direct port no2 fittings, twin injectors, and wanted everything modular (well I threw that in for free
)Basically he is paying for our time to develop a very bad @$$ intake manifold and it is much more bad @$$ than mine so I am going to have to run one on mine too
Will have 2 different plenum versions
Turbo Street/All motor (formed 3.5" plenum a little more volume than a eldebrock with a near perfect air distribution good to 80mm tb)
Pro Turbo (formed 4" plenum good to 100mm Throttle, much larger plenum than the street vs with near perfect air distribution)
The only thing that will be welded on the entire manifold is the plenum after that it is very modular similar to the hyper tune.
The runners/primaries/w/e you want to call them will be sealed with o-rings
There will be lefthand/righthand studs that we custom make that holds the plenum to the head flange (you only have 3 bolts to undo to disassemble the entire thing)
-James
Modified by JG-Fab.com at 3:28 PM 3/17/2007</TD></TR></TABLE>
awesome! This will be great for the peeps who want to make big power on E85 :-D