Budget reversed intake manifold

[_ShurikeN]

Hello, everybody.

I'm thinking of an idea of a budget custom Wagner-style reversed intake manifold.
The main requirement is stock position of all A/C components. That causes strict requirement of enough space for A/C condenser and very desired requirement for hydraulic servo (PAS) pump stock 3B/7A position.

I have here both 3B and AAN manifolds, 3B coolant manifold and 3B/7A PAS pump and alternator brackets. I have no aluminium welding stuff, so I will have to make measurments myself and take manifold to a welding shop.
The fist good idea is 3B reverting, but no space for PAS pump is left in this case. I don't want to transfer PAS pump to the place of alternator because of A/C compressor.
Any ideas what is the most effective way to design a manifold so It would act as good way as Wagner one (i mean arrangement, not flow), considering avaliability of 3B and AAN ones?

The first step planned is 3B reverting and then, maybe, a cut-out of room for PAS pump will be made. Or It's better to weld-on an AAN throttle flange at once?

I'm surely going to try smth, but just wonder, if anybody has got any inspiring pictures to look at.

[andy10v]

Iroz do a conversion service, still not budget though

http://www.irozmotorsport.com/aan-small-chassis-intake-mod/

You can see roughly where they move the TB.

[_ShurikeN]

I have seen this. Such conversion can be done relatively easily, and even better if throttle flange is moved forward further, but such scheme has some disadvantages.
You'll have to take PAS pump and alternator brackets from AAN + belt. Nothing scary about It, but issue with coolant manifold and hose is unclear to me yet in this case.

[andy10v]

Cut and welded one



SteveH did a home made cut and weld one on here, I think he is having an issue with the PS though?

http://www.s2forum.com/forum/showthread.php?t=59301&page=4

Others

http://www.s2forum.com/forum/showthread.php?t=58798&highlight=intake+manifold

Flipped and cut

http://www.motorgeek.com/viewtopic.php?t=8131

Another flip and cut

[quattro-nick]

this is my rebuild intake on a AAN engine with rebuild watermanifold
on the last pictures you can see the new support for servopump

[SteveH]

I'm going to have another go soon with my old 3B inlet as the donor. I think a 90 degree thick wall alloy tube will do the job. The issue with using the PAS pump and alternator setup from an AAN on the 3B is the harmonic damper. On the 3B it's a V belt setup and the AAN/ABY use a serpentine belt. That means you'll need to change the front pulley/damper and then should have the whole engine out to balance the rotating assembly.

[SteveH]

this is my rebuild intake on a AAN engine with rebuild watermanifold
on the last pictures you can see the new support for servopump

Your PAS pump mount looks nice. Have you moved the alternator to the other side?

What are you doing for PAS hoses as I guess the originals wont reach to that location? I know you can easily have different hoses made up but thought there were restrictors in the OE items?

[quattro-nick]

i build my alternator on the passenger side
the pas hoses are custom made without restrictors and that works fine to me
here a picture of the front.i put my alternator and paspump very low because my ic stands above the crankshaft pulley
p.s i have a b2 coupe quattro type85

[_ShurikeN]

Thanks for some helpful pictures to think about.

[_ShurikeN]

Looks like the very right stuff. Custom manifold with A/C and PAS pump bracket on cylinderhead. The image is surely from this forum.

[_ShurikeN]

A few more questions:
Is it a must to have idle valve nearby the throttle?
Is it a must to have IAT position perpendicular to intake flow?

[SteveH]

MY ISV is at the far end of the inlet connected by hoses the same size as OE and it doesn't make any difference to the idle.

[_ShurikeN]

Thanks!
And the IAT issue is clear since I have had a look at the AAN manifold: does not make sense.

[_ShurikeN]

Is it worth leaving standard hollow inside braces in the 3B manifold?

Like here on Thuppu's image:

[martinws]

My homemade reverse.
Had to make the 90degree elbow and moved PS pump to opposite side.