Time to go Stage II!

[Alky V6]

I don't know if this makes a difference, but I have a clearance between the rear edge of the front hood and the cowling at the bottom of the windshield. The clearance is about an inch along the driver's side, and then with the heater box removed, the right side is pretty wide open between the windshield and the rear edge of the hood.
Is the hole in the hood doing anything?

 

[Alky V6]

The port openings in the plenum lower section have been opened up to match the runners. The next step is to fabricate the port entry plates.

 

[Alky V6]

I'm brainstorming on these port entry plates, and you know,... they don't have to be aluminum. What about stainless?
These plates will also incorporate the port entry flares that will be formed from sheet metal.

Nevermind. Too expensive and too hard to work with.

 

[turbobitt]

I'm brainstorming on these port entry plates, and you know,... they don't have to be aluminum. What about stainless?
These plates will also incorporate the port entry flares that will be formed from sheet metal.

Nevermind. Too expensive and too hard to work with.

I still think Delrin or something along that design path would be trick. Just need to be a little more creative on the structure supports required to take some boost. I think the design would be very achievable and trick.
Allan G.

 

[Alky V6]

I still think Delrin or something along that design path would be trick. Just need to be a little more creative on the structure supports required to take some boost. I think the design would be very achievable and trick.
Allan G.

I've already used Delrin inside the plenum, and it doesn't hold up to the occasional intake backfire. It melts too easily.

 

[turbobitt]

How thick ? I would think 3/8 thickness would have enough mass to resist melting.
Allan G.

 

[Alky V6]

How thick ? I would think 3/8 thickness would have enough mass to resist melting.
Allan G.

In the fabrication section, I have a thread with pictures of the Stage I intake manifold disassembled. In one of the pictures there is a dark log shaped thing that was the first design internal fuel rail that I used for the mechanical injector nozzles. It was a pretty thick fuel rail, since I wasn't really sure about the strength of the Delrin plastic. Anyway, at one point when I was rebuilding the intake manifold, I noticed that the surface of the fuel rail had melted. Anything that I make that will be used inside the plenum, I do not want to end up melting, at any level.

 

[Alky V6]

The port entry plates have been cut, squared, drilled and tapped, and the layout for the port openings have been scribed onto the plates. I still have to cut out the port openings. That won't take much to do.
After the port openings have been cut, it will be time to work on the entry flares. YES! Finally getting to some cool stuff.

 

[Alky V6]

I've come up with a way to fabricate the eliptical flared entries from sheet aluminum. The services of Roscoe, the sheet metal guy, have again been retained.
He will bump brake the shape of the special eliptical curve into one long sheet of aluminum. Then, I will mitre cut the needed sections and build the rectangular entry by boxing the sections together.

 

[Alky V6]

This is an interesting link. Another bolt-together intake.
http://www.williamsenginedesign.com/home/products/intake-manifolds

 

[Alky V6]

The coordinates list for the elliptical curve.

View attachment 175819

Elliptical curve coordinates.
Bringing forward for reference.

 

[Alky V6]

The exhaust header flange has been drawn up.

View attachment 176759

Header flange dimensions.
Bringing forward for reference. I'm working on a mechanical drawing for the #5 exhaust flange.

 

[Alky V6]

Notes: 1.4-1.8 cubic feet of free air per minute for every hp that's developed. Many feel 1.8 to be the proper number.
K&N filter flows 6.5 cu ft/min per square inch of filter element. Dirty, it flows 5.1.

 

[Alky V6]

A series of pictures to show the clearance between the steering shaft and the number 5 exhaust port.

View attachment 183437View attachment 183438View attachment 183439View attachment 183440View attachment 183441

Number 5 exhaust flange to steering clearance.
Bringing forward for reference.

 

[Alky V6]

The #5 cylinder exhaust flange and stub are finished. A 2" OD tubing with a 3" CLR was used. The radius turn was extended through the flange.
The exhaust tubing to steering shaft clearance ended up being a good 1/4".
The exhaust adapter was used, unchanged.
Having the centerline of the plumbing follow the 7 degree up angle of the port relative to the mounting boss of the head helped a lot in having the pipe end up clearing the steering shaft.
The transition taper was added to the stub at the point where the stub just cleared the steering shaft, before the point where the turn of the stub piping reached 90 degrees.
Time to finish laying out the tubing paths and get some pipe ordered!

 

[Alky V6]

It looks like 26.75 will be the length of the primaries. This length includes the adapters, flanges, and the short length in the collectors before the runners actually merge. The tubing lengths will be 22".

 

[Alky V6]

The #5 cylinder exhaust flange and stub.

 

[Alky V6]

The intake runner entry plates are waiting for their flares.

 

[Alky V6]

The layout for the exhaust piping on the right side is pretty much finished. It took 3 configurations to finally come up with this one that required the least amount of bends.

 

[Alky V6]

Tomorrow, I'll be laying out the driver's side exhaust piping.