I've been doing intake manifold for my K24 RWD build and wanted to share the progress so far and hear comments if there are easy improvements still to make.
The starting point was a RAA intake that got me the first about 7cm from the head flange.
Doing this whit saw was good exercise
This is the piece I got
Then some cleaning was done to remove unnecessary stuff
I've been doing intake manifold for my K24 RWD build and wanted to share the progress so far and hear comments if there are easy improvements still to make.
The starting point was a RAA intake that got me the first about 7cm from the head flange.
Doing this whit saw was good exercise
This is the piece I got
Then some cleaning was done to remove unnecessary stuff
First cylinder pipe pointed too much towards rear of the head so that was straightened
I got nice velocity stacks from Aliexpress, 3 euros each.
There was sharp edge in the velocity stack, so that was blended in with rest of it
Next was plenum modelling
Plenum is going to be made from two pieces of 3" aluminium boost pipes by cutting them to suitable pieces
Got some parts from a friend who works in a laser cutting company
The pipes will be 50mm boost pipes. There is 90-degree angle, so I can cut a smaller, say 15-degree angle from it and put it towards the piece cut from the RAA manifold, to get the plenum to suitable place/height.
The velocity stacks and pipes have inner diameter of 46mm, velocity stack outer diameter is 70mm.
Length of the runners not decided yet need to get the engine to the car first.
"back wall" of the plenum is 100mm high and the "curved pieces" opened to 80mm so plenum is slightly "opening" towards the head.
Now I would like to hear if there are areas of easy improvements in my design.
And also recommendations of runner length.
Motor will be:
K24
Stock RBB head
Skunk stage 2 cams
about 12:1 compression
Boosted with E85, target about 500whp
K20 oil pump
No AC or PS
Since it's going to be boosted engine, the intake is made maybe a bit "small" to work well with low RPM.
At very high boost and air flows, flow and pressure distribution within the plenum become an issue. You might consider using a dual chamber design with a feed slit from an asymmetric small inlet chamber into the symmetric main chamber.
Been seeing these pop up on a couple different sites for Forced Induction applications. Basic idea is that they provide balanced cylinder filling, but for the K-series they would serve double duty by allowing us to run the throttle body facing the opposite direction, ideal for charge pipe...
www.k20a.org
Next, flat alloy plates tend to ballon and crack, plate and welds under cyclically applied boost. They either need to be strutted/braced, thick or also round.
Yes, the distribution of air might be a problem. Plenums are tapered from feed in to the other end just to combat this phenomenon. Air wants to "rush" to the end, so first cylinder would have less air (be rich) and last too much (be lean or knock) and therefore plenum is larger in the beginning to have more pressure to the first cylinders. My dimensions are a guess, so I might need to go to dual chamber design later.
I'm planning to measure individual cylinder exhaust temps (at least in dyno) to get understanding how well the distribution works.
Cracking is one issue as well, however I'm hoping with the modest boost of about one bar, the current design would live several years....
ps. realised that put this to N/A side of things although it's going to be boosted design, however the intake manifold experts are on this side, I assume
Turbo Plenums available from Jenvey Dynamics are suitable for a range of cylinder engines, click here to find out more
store.jenvey.co.uk
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