i hate to be 'that guy' to open a dead topic but i thought this deserved it.

probably one of the best posts ive read, very informing andprogression great work with the pictures and keeping us up-to-date... and great work on the car lol

10/10


edit: would be interested to know how much its making now tho

Cheers, there is a Fordmods SA dyno day next month it will be going on.

Due to the premature end of the filter socks, work has begun on the plenum.



For now it will route through where the aircon fuses sit, and have a pod on the end in the "airbox" behind the front corner of the bumper, where the bottom intake is. Should drop intake temps a heap, as it currently sits at double ambient whilst driving, so there isn't much air movement in the engine bay even at speed.

This will also make it easy to hook up once boost time comes (getting a 12mm flange from pacemaker next week to start a turbo manifold ) DOHC can wait, I think I have decided to try ITB+Turbo on the SOHC first.

Using a 90 degree 3" bend, I can weld a bracket on it to bolt it to the engine bay, then the pod will go on one end, and the other can hook up to the bottom of the plenum with a 90degree silicone elbow.


I already have the alloy for the runners, and the intake bit, just need to source a length of 3" pipe, ebay has em for about $30 in 2.1mm wall, but will try and find some local tomorrow, so I can get it done this week if possible, as I don't want to drive it without filtration of some sort.

maybe something like medium mesh over the trumpet would stop the sponge from getting sucked in????

It would, but it would still be sucking hot air.
Plus for the cost of new socks the plenum will be a heap cheaper. The drop in lower Air temps will more than make up for the loss. If you drive now for a while, then stop and open the bonnet for 30 secs, then drive again, the difference for the next 30 secs is a fair bit, so it definitely needs some fresh air.

Having somewhere to accurately measure incoming air temp will also allow me to fine tune the fuel and spark trim for air temp variations accurately, it's too up and down with what's happening in the engine bay, so I have it zeroed for now.

Time for the clear air box.....

What style of turbo manifold are you thinking of making.
And you have probability said this already but what kind of work do you do?
Because you have amazing detail in all your work.

Last edited by big dell on Sun Oct 10, 2010 6:42 pm, edited 1 time in total.

Looks good mate. That video sounds says it all. I'm really hoping uni doesn't keep me away from the Dyno Day.

Something like this would be cool, but now I want to try boost with the ITB's, the plenum will suffice for now N/A, and will be right once the rest of the turbo stuff is ready.

Similar to the 6-boost ones, been looking at merge collectors from the US now the $ is so good, but will probably have a go at making one, I have access to a couple of different vertical saws at work so it will be just time and practice.

I am hopefully picking up a 10mm flange (in stock) from Pacemaker this week so I can start playing with the angles etc, then they will cut me out a 12mm flange for the final.

I have found a couple of local places that do the sced 10 buttweld bends, gotta do some research on turbo specs, so I can figure out what flange to put on it.

I work in photography and teaching by the way.

Do 2 of the bottom inlets under cyl's 2 and 5.
It will avoid pressure loss at the ends (cyl's 1 and 6).

That plenum will cost you power. Air will not flow well around the sharp 90degree turn from ra, pipe to plenum. Check out the link, ignore the made in china bit and the fact its thick wall steam pipe. but you will understand the point i'm trying to make
http://image.made-in-china.com/4f0j00pe ... BW-Tee.jpg

Yeah, see your point, the more I have been looking at the FG manifold the more changes I am thinking about, along the lines of round inners on the joins. Might be able to press the flare on the runners and intake pipe.

The initial plan was a less complicated upside down version of the FG intake

keep it simple.

10mm x 60mm flat bar for the floor, drilled for each runner opening, machine a radius for runner entry into the flat bar, use 3.5 pipe for the plenum.
Cut out an opening in the pipe for the flat floor and feed air in a one end (3 inch air feed with radius entry in plenum.

bellmouths that stick out into the plenum disrupt flow.

I am going to lathe up an inside radius die, then press the runners into shape, then press and form it over a 3" solid bar, so I will be able to keep the round plenum and have the smooth inner radius, as in that T-piece


Runners cut, need to shorten the bend in the heater hoses, then it should fit nicely.