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home made sheet metal intake

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sparky1987

10+ Year Contributor
220
0
Feb 24, 2011
wellington, Ohio
I did most the fab work and machineing at home on this. Its all 6061 aluminum. I made the plenum individual pieces since 3/16'' 6061 cracks and breaks when you bend it. The flange for the head I had a friend of mine cut out for me on a cnc machine.
 

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How did you figure out the dimensions that you needed for the plenum? Or did you just kind of wing it based on what the other SMIM's look like?
 
I based the style off other smim I've seen but dimensions I just worked around the stock manifold and went from there no flow testing numbers but I did make a duplicate to have dyno tested
 
The welds look good to me. I purchased a SMIM and they didn't look that good, I even had a few pin hole boost leaks I had to JB Weld up to get it to hold boost.

Nice job, can't wait to see the results.

:dsm:
 
I hand formed them it was a pain in the neck the first few trys but I got a little system that works pretty good. Thanks for all the compliments on the welds I stride to keep my welds looking sweet I've been doing it for almost 10 years and I work for hmf racing welding for them so I weld alot hahahaha.
 
I'd imagine its possible to lose power on a poorly designed IM. Before and after tests would have been nice to see. I would have done it just for my own benefit. But the fab work looks top notch. Do the runners have veturi rings(think thats what they are called) inside the plenum?
 
I was able to form the tops of the runners to have a velocity stack form to them or atleast the best I could with what I have at home to work with. They go from almost 3in to 2.5in so it will definetly help speed the airflow up as it enters the runner and its all 1 piece so its smooth and I cleaned up and smoothed over any burn through I had after it was welded solid.
 

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I've sent a replica of the one that's on my car now to get dyno tested to a stock manifold. So hopefully ill have some information to share soon. Ive driven my car with the manifold on it and spool time and throttle response was noticably better then the stock manifold so I know I performs better then stock.
 
Yes we just got the manifold in and were about to take a look at it. From what I have seen thus far it looks like a very nice piece of craftsmanship. We have a couple cars we will be mocking it up to and possibly even be running it on the stock block record attempt car.
 
Excellent work, I commend your efforts with delight.

2.5" runners hmmm might have to see what i have ( i have my plenum and instake flange built, just never got around to making the runners adn timming it al up to be what is sometimes called "finished" LOL
 
There are harmonics in play that you haven't taken into account if you arbitrarily picked a runner length. I would suggest you do some fluid dynamic research.

So true and from other's tiral and error and general knowledge, the third harmonic wave seems to be the best to tune for on out applications due to the rev range, and many other fators which i'm not awake or bright enough to go into becaus eihaven't studdied them in a aocuple years myself when i started my project (which is why it lacks runners LOL )
 
I think it'll work great, ^^^^ the posts above i agree with., But i think shorter runners more high rpm hp, looks like a knockoff magnus to me......can"t go wrong with high hp and high rpm.
 
Pretty welds but....

Should have made the plenum bigger Rule of thumb is 1.5 to 2 times the engine displacement. So 3-4l moving toward 4 for higher rpm peaks.

I wouldn't have tapered the back on the intake like that. It leads to poor air distribution. Look at all the new style intakes, the top and bottom of the plenum taper, and the back stays parallel to the head.

There is a formula around for the runner length, I can't find it right now, but it works out to be in the 6-8" range for the 7-8000rpm peak power range.

Here is my intake. Its a 4" tube and its about 180cuin. The runners are like 8" On lower boost on my hx35 with D272's installed straight up, I saw peak load at about 6000 and maf hz peaked at about 8000. Where the stocker was at 5500 and 6500 respectively. Keep in mind that load and maf hz are loosely related to torque and hp.
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http://amsperformance.com/pdfs/intakemani.pdf

There are harmonics in play that you haven't taken into account if you arbitrarily picked a runner length. I would suggest you do some fluid dynamic research.

Nice. Leave strangely vague answers that imply that you know what your talking about, but yet fail to contain any meaningful information.
 
Everything I know and understand led me to what I made the runner length is about 6 inches I didn't arbitrarily pick a number I've been through automotive school as well as high performance engines classes.
 
I love how theres so many experts coming out of the closet.



Most of the first DSM sheet metal intake manifolds im pretty sure were trial and error. I highly doubt many vendors were really getting into the science of tuning an intake manifold on a forced induction engine to design theres. Now im not saying some of the high end vendors haven't since the begining, we know they have and do NOW. But shit give the guy a break, he made that shit himself with the help of a friends CNC machine. He claims it works better on his engine than the stock manifold, and I don't think he was asking, just how to improve it. So why can't people just say it's a nice piece of craftsmanship, displays great welding skills and leave it at that.

But shit since we got so many experts here, break out the expensive as #### fluidynamics software and lets test some shit out! There's only sound waves, pressure waves, valve timing, and general aerodynamic's/fluidynamics involved. Oh hell wait I think someone did that a few years ago and came up with a similar looking intake manifold design to one HKS made but I don't think released for an earlier Evo engine. I seem to recall it didn't get made either due to cost and complexity and pretty much impossible to create with sheet metal, would have to have been investment cast.:aha:

OP awesome welding skills, if your interested in the future (not so near) I might have a little fab work or something i'd like to contact you about. Mostly concerning fabing & welding aluminum brackets, and pipe connections.


P.S. Any idea when SIM is going to report back with there findings?
 
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