New Manifold with Intercooler
08-24-2003, 12:09 PM
#41
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I got in the base plate aluminum stock and started working it. But I found it to be too laborious for me at this time. And since this will need to be recreated at least three more time I decided to go for the sure route.
I am in the process of finalizing some CAD drawings and have talked to a shop nearby who will CNC the plate. So we should have repeatable machining of the base plate; which is the most important part.
The owner of the machine shop I am using turns out to be a motor head. He is currently doing parts for some tuners of the WRX among others. So he is interested in this and seems very flexible to the needs of this type.
Below is the image of the base plate and the dimensions; so if you want to make it yourself feel free to copy it. But be forewarned, this needs a few minor adjustments. Also, excuse the simple CAD work; this is not my area and I have only done this a few times:
Below are some snap shots of the current CAD output. I printed the plate as it sits so far and overlaid the gasket. In the second image with the gasket on top it is slightly bowed giving an impression that it is not lining up. By pushing the gasket flat and looking at it from directly over this area does show perfect alignment.
How I did this was by scanning the gasket, importing it into the CAD program, overlaying actual shapes created and then removing the image. This left me with a nice CAD drawing of what I need.
I am in the process of finalizing some CAD drawings and have talked to a shop nearby who will CNC the plate. So we should have repeatable machining of the base plate; which is the most important part.
The owner of the machine shop I am using turns out to be a motor head. He is currently doing parts for some tuners of the WRX among others. So he is interested in this and seems very flexible to the needs of this type.
Below is the image of the base plate and the dimensions; so if you want to make it yourself feel free to copy it. But be forewarned, this needs a few minor adjustments. Also, excuse the simple CAD work; this is not my area and I have only done this a few times:
Below are some snap shots of the current CAD output. I printed the plate as it sits so far and overlaid the gasket. In the second image with the gasket on top it is slightly bowed giving an impression that it is not lining up. By pushing the gasket flat and looking at it from directly over this area does show perfect alignment.
How I did this was by scanning the gasket, importing it into the CAD program, overlaying actual shapes created and then removing the image. This left me with a nice CAD drawing of what I need.
CNC is the way to go. 
08-26-2003, 06:52 PM
#44
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Looks like yours,...kind of 
http://www.racemarque.com/gallery/images/eng_tp_rt.jpg
it's here http://www.acura-cl.com/forums/showt...5&pagenumber=1
http://www.racemarque.com/gallery/images/eng_tp_rt.jpg
it's here http://www.acura-cl.com/forums/showt...5&pagenumber=1
08-26-2003, 08:22 PM
#45
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Scalbert, looks very nice. I know that there is a company making a very simaler setup for the GTP. You may want to check those boards and see what that setup is as well. Though they are using a roots type blower and from what I can see your using a cent. type. Very nice design though. It's nice to see that you're even going so far as to think about the air horn length, etc... Very nice!
Justin
Justin
08-26-2003, 08:27 PM
#46
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the comptech s/c isn't a centrifugal unit.
08-27-2003, 05:33 AM
#48
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Originally posted by JDawgX
Scalbert, looks very nice. I know that there is a company making a very simaler setup for the GTP. You may want to check those boards and see what that setup is as well. Though they are using a roots type blower and from what I can see your using a cent. type. Very nice design though. It's nice to see that you're even going so far as to think about the air horn length, etc... Very nice!
Scalbert, looks very nice. I know that there is a company making a very simaler setup for the GTP. You may want to check those boards and see what that setup is as well. Though they are using a roots type blower and from what I can see your using a cent. type. Very nice design though. It's nice to see that you're even going so far as to think about the air horn length, etc... Very nice!
I previously owned a GTP and know it well. The IC available for the L67 is wedged between the Blower and lower intake manifold as the blower sits in the engine Vee. That is not the case here as the blower is remotely mounted.
08-28-2003, 05:27 AM
#49
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Here is the layout for the main plenum. Everything will be welded together excluding the cover which will be bolted in place with 26 4mmx12mm bolts. This cover will allow access to bolt the whole assembly to the injector base.
The sides and low portions of the plenum will be welded to the base plate.
I'm taking the drawings to the machine shop later for them to go ahead and get started. All aluminum stock is in house so just the machining is left. I still need to add the provision for the IAT and MAP sensors mounting but that is minimal; I just need to take measurements.
The sides and low portions of the plenum will be welded to the base plate.
I'm taking the drawings to the machine shop later for them to go ahead and get started. All aluminum stock is in house so just the machining is left. I still need to add the provision for the IAT and MAP sensors mounting but that is minimal; I just need to take measurements.
08-28-2003, 05:29 AM
#50
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BTW, my plan it to highly polish the whole assembly when completed. I also want to get something engraved in the plenum cover representing the car...
08-28-2003, 06:11 AM
#51
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Originally posted by scalbert
I also want to get something engraved in the plenum cover representing the car...
I also want to get something engraved in the plenum cover representing the car...
"ThIs AcUrA will bEEt u!"
08-28-2003, 10:53 AM
#55
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Definitely only one at first. I need to be sure everything fits right and there are no drawbacks such as with the shorter runners, etc.
After it is on and confirmed I'll give the shop the go ahead to make the other three.
After it is on and confirmed I'll give the shop the go ahead to make the other three.
08-28-2003, 11:25 AM
#56
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Bueno trabajo mi amigo.
08-28-2003, 11:34 AM
#57
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Originally posted by scalbert
Definitely only one at first. I need to be sure everything fits right and there are no drawbacks such as with the shorter runners, etc.
After it is on and confirmed I'll give the shop the go ahead to make the other three.
Definitely only one at first. I need to be sure everything fits right and there are no drawbacks such as with the shorter runners, etc.
After it is on and confirmed I'll give the shop the go ahead to make the other three.
08-28-2003, 04:04 PM
#59
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Well, it may be delayed at least a week. The machine shop got in a large order and won't be able to begin until late next week or the begining of the following week. From there we will have at least three weeks before it is ready to be tested.
I guess I will go ahead and order the IC though just to prepare along with the 3 inch tubing/couplings.
I guess I will go ahead and order the IC though just to prepare along with the 3 inch tubing/couplings.
08-29-2003, 01:12 PM
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Originally posted by scalbert
The machine shop got in a large order and won't be able to begin until late next week or the begining of the following week.
The machine shop got in a large order and won't be able to begin until late next week or the begining of the following week.
08-30-2003, 04:58 AM
#61
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Ah, but I do need the CNC work after all limiting the potentials, I thought about doing it by hand again but there are too many current obstacles. 
08-30-2003, 05:27 AM
#62
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Ran into another problem; no one will make, at a reasonable price, the air horns. This is not large enough to warrant the associated costs, about $75 each (or $450 just for this samll part per system) so I have looked into an alternative.
On the factory manifold, on each side, are funnels. These should already be the correct spacing for the application. I just need to find a way to secure them. I'll order a set from the dealer and start working with it so they should be in by the time the base plate is machined.
This also gives an easier control on the height if it becomes an issue. But since the boost is present at very low revs with minimal throttle input the runner length really isn’t a significant factor.
On the factory manifold, on each side, are funnels. These should already be the correct spacing for the application. I just need to find a way to secure them. I'll order a set from the dealer and start working with it so they should be in by the time the base plate is machined.
This also gives an easier control on the height if it becomes an issue. But since the boost is present at very low revs with minimal throttle input the runner length really isn’t a significant factor.
08-30-2003, 07:33 AM
#63
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I don't really know much about the air flow around the horns, but what about putting a radius on the intake holes in the 1" thick mounting plate? You've got enough thickness in the material and with the CNC it should not be a problem.
09-06-2003, 11:39 AM
#65
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I've redone the drawings again. I wasn't comfortable enough with the hood clearance so I moved the access cover to the front side. Also, I used a flat front wall as there is more than enough volume in the main chamber. This, along with another minor change should give about ¾ inch hood clearance.
One other note, I am radiusing the runner inlets instead of using air horns as I can't get any at a reasonable price which fit. Every resource I have consulted supports the idea that this should be more than adequate (better than the stock runner inlets anyway).
I did ad a lip to the base plate for greater support of the IC and the IC is now shown in the drawings.
The shop should be getting started the first part of the week so I need to get the revisions to then ASAP (I'll drop them off Monday morning).
350+ WHP is getting closer.
One other note, I am radiusing the runner inlets instead of using air horns as I can't get any at a reasonable price which fit. Every resource I have consulted supports the idea that this should be more than adequate (better than the stock runner inlets anyway).
I did ad a lip to the base plate for greater support of the IC and the IC is now shown in the drawings.
The shop should be getting started the first part of the week so I need to get the revisions to then ASAP (I'll drop them off Monday morning).
350+ WHP is getting closer.
09-06-2003, 06:11 PM
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Heat exchanger will be in the lower portion infront of the rad..?
If so.
I like the polished.... scare the crap out a Mustang when they see me coming up to them at a red light..
If so.
I like the polished.... scare the crap out a Mustang when they see me coming up to them at a red light..
09-06-2003, 07:01 PM
#70
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Yes, the heat exchanger is the unit used to cool the coolant and is placed at the front of the car.
A polished unit often looks similar to an air/air unit indicating that it does have forced induction. So it all depends on whether or not you want to be known.
A polished unit often looks similar to an air/air unit indicating that it does have forced induction. So it all depends on whether or not you want to be known.
09-06-2003, 07:04 PM
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Well we never really discussed this subject...
I love the sleeper look... but I get alot of attention because of the tint and rims.. so why not.... not really important but is there a large price difference?
I love the sleeper look... but I get alot of attention because of the tint and rims.. so why not.... not really important but is there a large price difference?
09-06-2003, 07:09 PM
#72
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About $100 on average. Obviously we want to get the largest possible and be as efficient as possible.
BTW, the one thing I have shown yet are estimated HP number with ice placed in the reservoir. Yes, ICE... This would allow you to run at an intercooler efficiency greater than 100%. So you could go to the track in the summer and have manifold temps in the 50's.
Obviously the value is diminished in the winter but still interesting. In fact, in my old Typhoon when it sat out overnight in the winter, the vehicle was a beast for a while with the cold IC coolant.
My guess would be an additional 5% power increase with an ice filled reservoir....
BTW, the one thing I have shown yet are estimated HP number with ice placed in the reservoir. Yes, ICE... This would allow you to run at an intercooler efficiency greater than 100%. So you could go to the track in the summer and have manifold temps in the 50's.
Obviously the value is diminished in the winter but still interesting. In fact, in my old Typhoon when it sat out overnight in the winter, the vehicle was a beast for a while with the cold IC coolant.
My guess would be an additional 5% power increase with an ice filled reservoir....
09-06-2003, 07:14 PM
#74
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Originally posted by Smitty
I take it the red squares on top of the BLACK ones is the Reservoir?
I take it the red squares on top of the BLACK ones is the Reservoir?
Which red squares and black ones??
The reservoir isn't being shown yet. It will most likely be mounted near the driver’s side strut tower. I'm planning on using an aluminum tank, that way it can be polished if desired.
09-06-2003, 07:21 PM
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Originally posted by scalbert
BTW, the one thing I have shown yet are estimated HP number with ice placed in the reservoir. Yes, ICE...
BTW, the one thing I have shown yet are estimated HP number with ice placed in the reservoir. Yes, ICE...
