The '2 ton bugswatter' - back for a gentle stroke

[G60Rallye]

Looks stunning JP! See you at UD!

[JP]

am i right to assume that the whole idea behind this wonderful looking plenum is to aim for better equality of air distribution among the cylinders, better filling, less restriction and therefore overall faster spool and in number terms hp?

What would you be expecting on the current and most recent setup with the previous manifold if you put this one on? (+ mapping that is)?

Couldn't guess at hp gains.

However I would expect less/no surge in midrange compared to stock intake under high boost config.

I'd expect less pressure drop through to peak rpm on dragstrip and better on off boost response in and out of corners on a racetrack vs stock.

[A80Avant]

am i right to assume that the whole idea behind this wonderful looking plenum is to aim for better equality of air distribution among the cylinders, better filling, less restriction and therefore overall faster spool and in number terms hp?

What would you be expecting on the current and most recent setup with the previous manifold if you put this one on? (+ mapping that is)?

[JP]

Yes the current dual plenums that we're of the shelf solutions for other engines I've not found any upto scratch only some fabricated ones like repo's being good. Unfortunately wrong configuration for my bay. Single plenums on the other hand there are some good onea out there like the wagner one. Once again though wrong configuration for my setup.

As for ultimate dubs all being well I should be there. I'll update the thread with regards to UD closer to the time.

[campbellWS]

we're not worthy

as always JP, another level. I remember chatting to you on the phone about IM's and that you were not impressed at all after testing "named brands" for flow, and your lack of trust with other sources, I knew you were going custom!

And big congrats on having one of the most desireable builds on this forum!!!!Has got me through boring days at work many a time, mate your attention to detail is pretty much unmatched

are you going to make it to ultimate dubs this year? well worth the trip down just to see it !!!!!

[JP]

very nice work. I hope it will translate to good numbers after the installation. Ideally, if no other change is made, it would be good to see the before and after hp and torque to see the differences

First of thankyou

Unfortunately before and after has not been viable.

However from flow testing a head with a stock ported AAN intake the flow figure on a ported big valve intake port with moulded clay on the opening is 12% better than one with a ported intake manifold attached to it.

Whereas when I flowed Jeffers head with the identical trumpet stack attached it lost no cfm over flowing the head with moulded clay.

Flowing the trumpet stack on it's own flowed 50% more than the ported big valve inlet.

And blowing through the throttle body and measurimg airspeed exiting the runners they measured with 2% across the board.

So I know its a distinct improvement over stock. Once mapped I've also got a benchmark comparison from Hamish who has the same head and exhaust manifold but catcams wagner intake and a hta3582 with same wastegate and hotside. Whereas I'm running my modded 7A cams with a hta3586.

So hopefully amongst all the info it will provide me with the necessary comparisons.

[A80Avant]

very nice work. I hope it will translate to good numbers after the installation. Ideally, if no other change is made, it would be good to see the before and after hp and torque to see the differences

[JP]

Well with the main plenum done I set about sorting the primary one out.
First locating where the throttle body was going to sit.



Taking care to line up all transitions between components to avoid unnecessary turbulence



Realising that the vast expanse had the potential of ballooning out under boost pressure. I knew I needed some sort of internal support structure so decided to get these to double up to help disperse air through the primary plenum.







With the top plate in place it was time to kiss the internals goodbye and make up some side plates.



With the final hurdle being the such things as air temp sensor, co2 spray bar under the intake fins



Along with vacuum take off's, throttle cable support and mounting points for the sexy billet fuel rail supplied by Will @ VRS Northampton.





That's it pretty much done now, just waiting on the swaged tube to arrive for the carbon cannister breather and the idle air valve before I can do a final polish on it and get it clear anodised before final installation

[Christophski]

Mmmmm, that looks v v tasty!

[JP]

Little bit more progress on the intake.

Picked up the main plenum top plate from G23 Engineering on saturday and got straight on with the fitting




And to try and stay at my normal pace without interfering with work pulled a late one last night to part weld in the end plates to start checking throttle body location later on today when I got to drop some work of

[JP]

Its of a late audi sort of leaving it to will @ vrs he knows his brakes when it comes to custom setups.

[mushasho!]

the stock rear callipers bracketed to take 330's on the back.

Which disc would you be using for this?

[Jeffer]

I will create a new thread tonight with more info on this.
Don't want to pollute JP's thread

[Thuppu]

Great fabrication JP. Looks awesome and I love the flow straightner.
Sorry to hijack your thread JP. But if anyone is interested I can supply the billet headflange and baseplates so people can fabricate there own.

How much for a kit?

[Jeffer]

Great fabrication JP. Looks awesome and I love the flow straightner.
Sorry to hijack your thread JP. But if anyone is interested I can supply the billet headflange and baseplates so people can fabricate there own.