I'm in the concept stages of a custom intake manifold for another application. It's an application that would HIGHLY lend itself to benefiting from a dual stage manifold. Trying to bounce around ideas, the difficulty lies with the butterflies, rotary valves or whatever type of unit is involved.

Searching around it's pretty typical to have the GSR style butterflies, which lead to turbulent conditions and fuel atomization problems and the K20 rotary style valves. The GSR setup is clearly easier to fab and create, but the rotary valves are not, yet the flow characteristics of those are clearly superior.

With rotary valves and units with sliding style plates I see the opportunity for sealing issues when created in a custom manner. The butterfly approach is simpler and will likely be employed in my initial build.

Anyone have any information or anything to offer? Are there any sources for individual sealed rotary valves that could possibly be used? Anyone ever come across a custom built dual stage intake mani?

This is kind of a 6 month or so project. I've finally met my end in the Honda world for a while. I'm burned out beyond belief and just simply need to build something else. I know what that something else is, I just need to sell my current Honda, which isn't exactly easy in this economy...noone is buying anything it seems.

 

The SVT Focus has a killer design that works really well:

 

try and look up what you can on the cosworth xfe engines that were employed for the better part of the champ car world series before it ended. they used a single throttle body at the intake manifold plenum opening paired with throttle barrels built into the heads. the tb was to help control the amount of boost the engine saw.

 

Yeah, the SVT is pretty innovative. I like the K20's manifold design as well though. It's just that, in terms of fabrication, neither are easy. I'm trying to find that mix of function with moderate ease of fabrication, and butterflies seem to be the easiest thus far. That's why I'm wondering if there are any valves for something available on the open market that may work.

 

^^^ LOL Never thought i would hear any of you say something good about a Focus haha. but ya i can get you some cut away pics of the SVT focus one im pretty sure i have laying around

 

Yeah, anything you can add would be helpful.

 

Ok let me go look in a little

 

why dont you use ball style valves instead of butterflies, that way there would be a nice clean airpath. and its not like you ever need to be partialy open, just on or off

 

That's what I'm considering, but I don't want to have to custom make the entire valve. I don't have access to CNC, just basic mill and lathe, and of course TIG. If I could source ball valve units in aluminum, or hell even steel, that appeared able to be made to work I'd consider them.

Like I said, the ball valve is superior, but the butterfly is much simpler in design.

 

you could build something like i have seen on sport bike engines where an actuator raises or lowers a 2nd set of velocity stacks to increase the runner length

 

I've never seen this implemented. I've certainly thought about that design, but couldn't really conceptualize how to make it work. Any links? I'll do some searching.

EDIT: Found some interesting F1 based stuff. I have 27ft of 12k x 12k twill left...I could try it but it'd be a HECK of a build project.

 

Ever consider a static multiple length setup? Similar to the Hayabusa and other Suzuki bikes. Make cylinders 1/4 one length, and 2/3 the other, ideally you choose one length for target resonance at peak HP, and the other at peak TQ. The magnitude of the peak will not be as great as if all four runners were the same, but at least you have both key RPM regions covered in terms of harmonics.

One setup we considered on a Formula SAE motor was using an e-Throttle servo motor to control a sleeve that lengthens/shortens a given section of intake runner. Just run the feedback off your TPS so it is porportional to throttle input, or use a flexible output on your EMS (assuming you have a standalone).

 

the top portion seals on the lower portion to lengthen the runners.

you could elaborate on this idea and have the top part slide inside the bottom for a variable length instead of short and long

here is a better picture

 

Wow...that above concept is pretty simple...interesting.

92TypeR...I'd considered the multi length runners. I've seen some CanAm applications from back in the day, but I just simply like a multi length runner better, as that's the newer and more effective technology.

I'm looking and saving some various pictures. I need to get myself together with solidworks as my skills are beat. I have more time now though, so I think I'm gonna get my sh*t together on that end to come up with some concepts.