Just finished up an manifold for a guy who is working out the details of some budget ITBS for the Miata 1.8L manifold. This was the prototype manifold for him. Here are a couple of shots of it.











I think it came out pretty good... Being a prototype it isn't quite perfect, I need to modify my fixtures as the outer runners had moved a tad when I had welded it all it but the ids still match of fine because the itbs are a bit smaller than the actual runners.

BTW this is my first time doing one of these.
-James

 

man that looks pretty cool

 

Why such a large piece of Billet for the logo?

What type of material was used for the runner?

 

+1 and where did you get the runner bends?

 

Cause thats the only name tag badge I had laying around lol. Didn't have time to machine what will be on the final products (1" tall, 10" long, 1/4" thick engraved instead of embossed)

As to the runners I love all the work that http://www.mandrel-bends.com/catalog/ produces. CRMB is the shiznit!

The runners were built from 2 2" od 11 gauge 90 degree bends and 2 2" od 11 gauge 45 degree bends, all 3" clr.

-James

 

Cool stuff, but I agree the badge is a little overkill.

 

cool stuff.. are you using 1/8 tungsten? beads are massive

 

Yeah I am still waiting on my new 3/32nd hybrid alloy tungsten to come in

So all I have right now is 1/8" pure tungsten.
The runner to head flange was done at 275 amps with 3/32nd 5356 filler
the butt weld runner welds were done at 125 amps with 1/16 5356 filler

 

Ditto on the name badge being a bit over the top :-)

But also, I got a TON of sh*t back in the day when the "DIY", "Cut and paste" ITB's first came about for having bends in the runners. I am told this is a HUGE no-no with ITB's as far as a performance standpoint. I made a ITB set up for a B20/VTEC with the "cut and paste" method, they made only 2 more hp peak than his Skunk2 manifold (but made his prior peak HP about 2000 rpms sooner in the powerband), we later did a full on straight runner ITB set up and it made upwards of 15 hp improvement. Just my two cents.

 

Pure on these inverters is a no bueno.

 

The customer had supplied the throttlebodies so spacing on them was not adjustable.

I have since looked up itb setups and it looks like the 4age toyota has some itbs that are not interconnected so you could easily space them wherever you wish, also they are quite a bit larger than these motorcycle throttlebodies. I am sure you know how it is having to do what they want, not necessarily what is right...

As to running the pure tungsten, the only other thing I have is 3/32nd 2% throicated (red) and it won't produce a small ball on the tip, instead it produces like a hundred ultra small *****, kinda looks like a crystal or something. It will let the arc wonder a bit like that. I know the whole purpose of the inverter welder is to be able to use a tungsten that is nice and sharp but you gotta do what you gotta do...

 

Nice work
275 amps tho **** thats alot of amp's

 

I like to run my welds hot, I would much rather a bit excess penetration that I can port out and clean up than to run it cold and have it crack and fall apart on me.

 

GSXR ITBs are independent with some adjustment to their spacers. Thus why you'll see them preferred over ones above and other options.

 

Oh ok i like to try the same thing but i can never get a good weld out of it. .

 

looks good. It looks like you have some kind of bushing in the holes of the flange.

 

looks like where he had the nuts/bolts holding it in the jig. I hate it when that happens, it can sometimes be hard to remove completely, and makes the part appear to be used.

And yeah James, I hear ya. When the customer supplies the part and tells you what they want, you gotta go with it sometimes. What about the injectors? top feed? or are they bolted to the head rather than the IM? I also hear having injectors close to the combustion chamber is a no-no on ITB's, I haven't ever tested it myself, but I know TWM, Toda, and probably every other big name ITB company spaces the injectors a lot farther up the runners. Your customer will probably be jumping up and down excited when he feels the throttle response he gets from your ITB's, and I'm sure it sounds pretty wicked too. You haven't heard VTEC crack until you've heard it crack with ITB's :-)

 

Nice work man, is that schedule 40 t6061 on the runners? Where did you get your manifold flange or did you guys have it made. Are you having to port out the flange very much to match the runners?

 

Except these are going on a miata

 

It is the Miata 1.8L they have the factory injectors in the head. I think he plans on using the duel stage injectors on the itbs themselves though. I built this for a guy who is an electrical engineer who is designing a complete low budget itb kit for some other company, the itbs have a drive by wire extra butterfly in them which actually also acts as the iacv, the guy I built this for makes a electrical box that controls that as well as controls the duel stage injectors.

 

Actually they match quite well, the ports on the miata head flange are the same size as b series exhaust ports. Also the material is 2" 11 gauge tubing rather than 1.5" schedule 10 pipe (which has a 1 7/8" od) so I got lucky and my forming tool I use for my pipe for turbo manifolds worked perfectly on the 2" for this setup. As to having to port out much I only had to port on the insides of the bend where the material thickens from being bent, after that it was just about 5 minutes with a 120grit flapper wheel on my die grinder and it smoothed out perfectly.

 

You guys are really going all out intake manifolds these days. Is this the new business plan - BMC Intakes?

 

Yes sir, I am hoping that within a year they will be mainstream enough so that I can shut down turbo manifold production.

Either that or I am also considering having yall cnc mandrel bend the runners for the turbo manifolds

 

looks awsome

 

whys that?