New intake manifold
 

I have developed a new intake manifold for 1g's. I have spent the last 2 1/2 weeks designing it in the CAD system at work. It is set up for a gasket matched head and has tapered runners. The flanges are 3/4" thick and CNC machined. The runners have a 1/2" radius going into them and the TB flange has a radius going into the plenum (noone else does this). It is all 6061 aluminum and TIG welded. I have TB flanges for both a stock or Accufab 75mm TB. It has 4 vacuum ports on it. It also has built in mounting points for the coils! Noone else does that either. It faces the coils towards the engine, so it should look sharp. Fully polished of course!

Martin from AMS has been developing an intake manfold for the EVO and I hadn't seen his posts until last night. Surprisingly we came up with nearly identical designs! I guess my research paid off. He tried many different designs and settled on the one very similar to mine. Mine has a little bigger plenum than any other manifold on the market, and should work better with a 2.4l.

I would like to know who is interested in buying one. I need to decide how many I need made up for the 75mm TB. I am guessing just mine though :) The parts are in production at the machine shop right now and they should be done in 3 - 4 weeks max.

I have a snap shot of the bottom of the plenum that hooks into the runners on my webisite http://www.jetscustoms.com . The site is still in progress, but you can see a bit of it on the front page. I may put a few more shots up here.

Price is going to be $450 or under.

Re: New intake manifold
 

I don't want to sound like an ass, but are any of these manifold designs patented or in the process of being patented (i.e.- Martin's). It definitely wouldn't be cool to see you get in trouble for having something so similar.

Re: New intake manifold
 

Jakey designing a intake manifold is like re-inventing the wheel anyway. No matter how you make one you would be copying someones previous idea. There are a few unique ideas going into this intake manifold that have not been shown or talked about yet as well, that will seperate it from some of the others.

CRAIG

Re: New intake manifold
 

well I'd possibly be interested in one, but I would want to see it first. How long are the runners? When you say the runners have a 1/2" radius going into them, I really am not sure what you're saying, so could you maybe break it down Barney style for me. This uses velocity stacks? Is it just a square plenum, or does it taper like the magnus? I'm really curious about it. I wish you had a picture of what this will look like.

Re: New intake manifold
 

It definately isn't similar enough to be a patent infringement and I am sure he isn't patenting it anyway. The runners are a total of 6" long. The style is similar to a BJ's manifold. The radius'd runners act much like a velocity stack and the runners are tapered like a velocity stack. The radius is in the pic on my website. www.jetscustoms.com

I am just trying to guage interest right now. I will definately put up some pic's when they are done. The machinist begins production on Friday and I should have the parts Mon or Tues. Hopefully I will have the press bent parts by next weekend.

Re: New intake manifold
 

OK sounds cool. I was planning on getting that JM Fabrications one. But if the one you built can match the quality of his, then I'd be game for one. This still wouldn't be for a couple months though.

Re: New intake manifold
 

Do you have any pictures of a completed model?

Re: New intake manifold
 

I didn't put the whole assembly together, but here are some screen shots of a few of the pieces. The runner and then the bottom of the plenum that connects to the runners.

Re: New intake manifold
 

Looking good. Solid works is cool beans.

~John

Re: New intake manifold
 

Have you thought about trying any sort of FEA, heat transfer, or fluid dynamics analysis with your design?

Re: New intake manifold
 

The problem with the flow analysis is that it can't include a lot of the real world things that you see. There is no pulsed flow or air pressure waves. Others have tried doing the flow analysis, but found that it does not hold true on the dyno. Solid Works has that built in, but I don't think it is worth the effort to set it up for it. If it could give good results, I definately would.

Here is one of the cool things that I include on my manifold that noone else has. Coil mounts! The L shaped sets of holes are to mount each coil. The wires will point straight towards the engine. There are also 3 vacuum ports on that end, they have enough room between them to use a 90 elbow, so the lines will be nice and clean. There is also a vacuum port built into the top picture to supply the BOV. It is closer to the BOV up there to make it react faster and keep the engine bay cleaner, because of the shorter hose.


All of the pieces have a milled out edge like this so it all goes together like a jig-saw puzzle. It also allows for a better weld.

Re: New intake manifold
 

Here are some of the pieces in real life! This is the 2 different throttle body flanges and the base of the plenum that attaches to the runners. The machinist did an awesome job!

Re: New intake manifold
 

correct me if im wrong, but why does it seem like there is an excess amount of chatter? Was he milling too fast? Or did he just kinda get it done because its prototype? Or does it just look that way! ( thats very possible)

Re: New intake manifold
 

Are you talking about inside the radius? The flash really makes that show up. Looking at the part, it is very smooth. I updated the picture with one that didn't have the flash. The pic is also larger than real life, so remember that.

Re: New intake manifold
 

Dont get me wrong, that looks extremly nice. i know how hard it is to run a CNC and get exactly what you want out of the deal. Most people think its just punching some buttons. its really Lots of math, thought, planning, and specing.

The reason I asked was because i think it was there, and I thought it might effect the way it operates. On the other hand, it may effect nothing.

Re: New intake manifold
 

You can't even feel any chatter with your finger. It is just the camera making it stand out. These are also the first prototype parts, straight off the mill. All production parts will be polished before they are assembled, so if anything like what you are thinking is present, it will be taken care of. We are making a few changes to the production parts too.

We are also going to add another option on. You will be able to order the runners so they mate up with a stock head, or they can mate up to a gasket match ported head. The stock one will also be able to be ported out at a later date if the head ends up getting ported. It is going to work very slick.

Re: New intake manifold
 

Flanges look really nice JET!

Re: New intake manifold
 

Thanks Mike! I actually have the whole batch back from the machinist now. I should have some better pic's up within the next few days. I have had a few customer cars come in this week, so they are first priority. Hopefully I can get back on the intake manifold project on Wed.

Re: New intake manifold
 

Alright, all of the flanges are made and I just received the shoes (outsides of a punch press die) to make the sheet metal parts. I have a 45 ton air operated hydraulic press on the way to form the runners and plenum. I now just need to make the inner part of the punch press dies so that I can bend the runners and plenum. I hope to have this ready to go by next weekend, then it will just be welding them together!

I should hopefully have some done by the end of the month at the latest.

Re: New intake manifold
 

do you have a picture of the finished product?

Re: New intake manifold
 

Nope nothing done yet. I need to make the runners and plenum first. I should have something done by the end of May.

Re: New intake manifold
 

Its looking good so far man. I can't wait to see the finished product.

Re: New intake manifold
 

Well, a month after I paid for it, my 45 ton air operated hydraulic press finally arrived! The thing is pretty bad ass and will be used to press the runners and plenum for the intake manifolds. I already had the "shoes" for the dies, now I just need to make the insides of the dies. I should hopefully get that done next week, then I can start pressing out some parts. That will be the last thing I need to complete the intake manifolds!

Re: New intake manifold
 

Congrats! Glad it finally showed up, thought you might be heading to Cali.

Re: New intake manifold
 

Any update on a finished product?

P.S. Did you end up using that PDF I sent you on NABR for any of the designs?

Re: New intake manifold
 

Sorry, I have been extremely busy doing other customer projects and haven't had time to finish these up yet. It is my top priority after the current projects though. Hopefully soon!! Customer cars always come first though.

Re: New intake manifold
 

hey justin, you can count me in for one intake and a 02 housing, and i like your web site keep in touch with any new products see ya tom

Re: New intake manifold
 

Thanks Tom! Business has been very busy, so the intake manifolds are still a ways out. I will have 1g AWD turbo back systems fully jigged up and ready for production in another week!

Re: New intake manifold
 

3" SS cat back + 3" SS test pipe + 2.5"-3" SS w/flex downpipe? :D

Re: New intake manifold
 

I don't mess around with 2.5" :D I will be making long cat-backs that eliminate the cat (DP backs). I will also be running 3" O2 housings (yes, 3"!) and 3" dp's. All SS of course, even the flanges. The DP's do have SS flex sections too.

Any more questions about exhausts, please put them in the exhausts thread. Thanks!

Re: New intake manifold
 

So do I get a prototype manifold for use at the SO?:p

Re: New intake manifold
 

The manifolds won't be ready for the SO. I am basically booked all the way through the end of Aug. right now. I could fit a few more small jobs in, but not much.

Re: New intake manifold
 

do you have those intake manifolds done yet? and not to be a repetitive prick but your web site still isnt working.

Re: New intake manifold
 

Yes Jet. I'm a new member and wondering if you have pics of the finished product and what the ballpark is to get my hands on one.

Re: New intake manifold
 

Yeah, JET. Where's the love?

Re: New intake manifold
 

Bump.

Re: New intake manifold
 

Sorry guys, my full time job is nuts in the winter. I have not had the time to put towards projects like I had hoped to. Things should slow down within the next month so I can spend more time in the shop, but I wouldn't look for an intake manifold for a while. I have several projects that need to get done first. Realistically it will be around 3 months, if all goes as planned (disclaimer :P ).

Re: New intake manifold
 

Wow, I've been following this thread for QUITE some time man, hope this thing comes along it looks great!

Re: New intake manifold
 

Wow, I didn't realize how long ago I started this project! My day job has changed significantly and time is going to be tight even in the summer. I am probably going to hire out making the dies, since I am probably not going to be able to do it.

Re: New intake manifold
 

I'll demo it for you when it's all done, and I won't charge the normal fee ;)