Here is a little piece I have been working on for my UrS4 project. These parts are all CNC laser cut. The bent plenum parts are CNC brake bent. This is designed to be completed with some RMR runner tubes and a stock head flange. If I feel ambitious enough I will do a billet head flange. Plenum volume is around 6 liters and the throttle body will be a 3" 4.6 mustang style unless I do that from billet/scratch as well. Bores on the top hat are for additional/shower injector bosses that will be sunk down towards the ports. Im also going to machine radius transitions into the plenum base.

 

Niceee! I really want to try an intake manifold one of these days....gotta practice my aluminum!

 

I'm interested to see how the plenum-mounted injectors work out! I have always wanted to try it out on a street car but never had the chance.

 

Well the bosses are just for secondary injectors. The primaries are buried in the head flange. Hopefully there will be no ill affects from doing it this way.

 

You should look at raising the bell mouth up off the floor. It will make more power and create less turbulence around the throttle bores.

The plenum mounted injectors should work fine. Porsche used them years ago on some of their race cars. The big issue will be getting the cross over point tuned correctly, so that it smooth and doesn't lean out the motor too much.

 

Yes sir. I was shooting to have this look similar to the Audi intakes on the 80's rally beasts. I was planning on either switching to stacks or milling the transition and cutting the floor lower just as you suggested. Thanks for the information.

 

Just buy the bell mouths and bore the holes in the floor of the plenum, insert the bell mounths and weld them in place. Much easier.

 

With RMR oval stacks at $40 a pop, I'll stick with some one-on-one time with the CNC.

 

Wow man, Very nice work. I can't wait to see the finished product!

Jay-O

 

Looks sick!

FWIW, Kinsler has a new plenum mounted intake and I'd trust them to know whats up. You'll be fine

 

Why it reminds me of the Dahlback unit.. u are using 10g aluminum right , I have always wonder if it will hold up?

looks good

Gil

 

thats SICK as hell!

 

Everything is .125" save for the inlet tube which is 16g/.065" and the plenum floor which will be machined .5". I had designed some little bulkheads for strength on the inside, but I probably won't install them unless a backfire blows the thing to pieces.

 

Did u used Solidworks to design it? Did u test it? flow and strength ?

Interested on the outcome tho!

Gil

 

Looks like a cool design. Any practical reason for the additional injector row?

 

I did use SolidWorks for the model. No design to speak of except for the plenum volume. This will surely be an iterative process i.e. if airflow is off make a new one/if it blows to pieces, make it thicker. I think it'll be OK for a first stab. As for the additional injectors I just wanted to split up the load (and I love the way it looks). The turbo is a GT42 102mm so there will be plenty of need for fuel.

 

Awesome work man. I love it when people build stuff on their own and test it. Not enough of these people out there. I would definately flow test this and would love to see a CFD done too, but props for you to getting it done.

 

Love the angled inlet to the plenum.

5 cylinders are strange beasts indeed. Gawd I want an UrQuattro...