1.4L Intake manifold design/development

[jeff@racerxfab]

We started on the intake manifold roughly 2 weeks ago and we are well underway with machining components for our prototype manifold. From our CAD data and flow analysis, it appears the OEM intake manifold is bias to cylinder 1. We have done our best to correct for this with our current design. Does anyone know if cylinder 1 tends to run a bit lean and cylinder 4 a bit rich?

From our previous experience building turbo intake manifolds we typically like to see a plenum volume of 1.5 to 2 times the engine displacement. The intake manifold we are building falls right in between those assuming it will fit. The runner length will remain close to OEM, and the diameter is designed to work with the intake valve size.

PCV:

We are open to suggestions on the PCV routing. The flange incorporates a NPT thread which we plan to reroute to the back of the intake manifold including a check valve. From what I have read, the PCV is a common issue on the OEM intake manifold so if we can correct that now it would be great!

Vacuum ports:

We will be incorporating several of the OEM fittings on the top of the manifold. Are there additional NPT ports that you guys would like to see? We typically add a few 1/8 NPT, 1/4 NPT and sometimes 3/8 NPT.

 

[Sonic Attack]

Jeff: Thanks for jumping into the new-to-X Sonic platform. From what I've seen, the intake manifold would be a good idea, since the forum has seen a series of failures from the injection molded intake splitting along the seams under boost. Improved flow and durability are good things!

 

[jeff@racerxfab]

Jeff: Thanks for jumping into the new-to-X Sonic platform. From what I've seen, the intake manifold would be a good idea, since the forum has seen a series of failures from the injection molded intake splitting along the seams under boost. Improved flow and durability are good things!

Thanks! We are hoping to pick up a bit of power from it as well, I'm sure we will all find out when we start testing.

 

[EyeluvSmegma]

Thanks! We are hoping to pick up a bit of power from it as well, I'm sure we will all find out when we start testing.

This would be the BEES KNEES! Veddy excite (Borat voice)

 

[greg51]

intake

Are you going to use velocity stakes in the cylinder runners ? Put a port in the crankcase vent so you can install a check valve to the back of the throttle body and the stock outlet for 5/8" hose to turbo check valve to vent crankcase.
what kind of time frame are you looking at to bring to market ?? You have my interest Greg

 

[jeff@racerxfab]

Are you going to use velocity stakes in the cylinder runners ? Put a port in the crankcase vent so you can install a check valve to the back of the throttle body and the stock outlet for 5/8" hose to turbo check valve to vent crankcase.
what kind of time frame are you looking at to bring to market ?? You have my interest Greg

Greg, we machine the velocity stack directly into the base plate this works quite well and reduces additional welding. The flange does incorporate the crankcase vent to a standard NPT fitting, we have sourced a check valve that we will include with the manifold.

 

[Tormach]

Are you going to use velocity stakes in the cylinder runners ? Put a port in the crankcase vent so you can install a check valve to the back of the throttle body and the stock outlet for 5/8" hose to turbo check valve to vent crankcase.
what kind of time frame are you looking at to bring to market ?? You have my interest Greg

I am with you on this Greg.

You've def piqued my interest opcorn:. I think quite a few people on FB Gamma II will be interested as well.

 

[ScarabEpic22]

Fix the PCV problems as well you say? If I'm going to spend $100 on the fix and maybe $250 on a new stock intake manifold, this has my interest.

 

[whitesmoke]

$$$$

How much will this piece of engineering cost? Lol
We have not noticed any difference between any of the cylinders as far as rich/lean, all burn pretty much exactly the same. We have 418 full 1/4 mile passes on this car in the past 3 years, pull plugs couple times a week. Since the injectors are at the port they will all deliver fuel exactly the same, and since its under boost pressure which is stabilized across the board there really is no reason for any cylinders to run richer or leaner than others.

 

[jeff@racerxfab]

How much will this piece of engineering cost? Lol
We have not noticed any difference between any of the cylinders as far as rich/lean, all burn pretty much exactly the same. We have 418 full 1/4 mile passes on this car in the past 3 years, pull plugs couple times a week. Since the injectors are at the port they will all deliver fuel exactly the same, and since its under boost pressure which is stabilized across the board there really is no reason for any cylinders to run richer or leaner than others.

Thanks for the feedback!! We did notice the airflow was slightly bias to cylinder 1 compared to cylinder 4 and that was the reason behind the question.

We are hoping to keep the manifold cost right around $500 to $550, we should have a good idea on pricing once we finish the prototype.

 

[SUPERDAD3114]

Thanks for the feedback!! We did notice the airflow was slightly bias to cylinder 1 compared to cylinder 4 and that was the reason behind the question.



We are hoping to keep the manifold cost right around $500 to $550, we should have a good idea on pricing once we finish the prototype.

I’m in. If/when you come out with it, I will get it. Seeing people are selling ported stock intakes for 300-350. I feel 500-550 is right on point. I’m in. If you need someone to take on the first model for testing I’m in. Just pm me


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[RMinNJ]

If its a drop in replacement for the stock intake manifold (which will eventually need replacing because of the orange check valve) with all the stock connections needed... then yeah , I could see lots of folks wanting one.

It being shiny and not black plastic I can see my dealer blaming anything and everything on it including world hunger..

 

[Big Turbo Sonic]

Is this going to be a drop in and go product? By that I mean no tuning necessary? Seem like tuning would be required.

 

[jeff@racerxfab]

If its a drop in replacement for the stock intake manifold (which will eventually need replacing because of the orange check valve) with all the stock connections needed... then yeah , I could see lots of folks wanting one.

It being shiny and not black plastic I can see my dealer blaming anything and everything on it including world hunger..

Is this going to be a drop in and go product? By that I mean no tuning necessary? Seem like tuning would be required.

This may be a drop in product but currently we are under the assumption it will require tuning due to variations from the OEM manifold. We will see how much variation when testing begins.

 

[Big Turbo Sonic]

This may be a drop in product but currently we are under the assumption it will require tuning due to variations from the OEM manifold. We will see how much variation when testing begins.

If tuning is required how is it going to be marketed to people who dont have tuning capabilities such as hptuners. And for people who do have hptuners?

 

[jeff@racerxfab]

If its a drop in replacement for the stock intake manifold (which will eventually need replacing because of the orange check valve) with all the stock connections needed... then yeah , I could see lots of folks wanting one.

It being shiny and not black plastic I can see my dealer blaming anything and everything on it including world hunger..

If tuning is required how is it going to be marketed to people who dont have tuning capabilities such as hptuners. And for people who do have hptuners?

First we will need to be through testing to find what the compatibility is with the OEM ecu. We will be using hptuners for our vehicle, we are open to suggestions if you have any?

 

[jeff@racerxfab]

We were able to tack up the manifold and check for clearances in the engine bay. Now we will cut it apart and start final welding along with cutting a few more pieces. We still need to cut the vacuum plate, evap fitting, 1/8" NPT weld fitting, and the MAP sensor fitting.

Any feedback is welcome, if you would like to see any additional fittings now is the perfect time to let us know.

 

[boostiboo]

i just wanna know if i can keep my BNR tune/if BNR will be able to add this to their tune and if it will interfere with the plumbing of hard charge tubes (BNR) cause it looks like the TB is in a different spot, but that might just be my sleep deprived brain in action.

 

[jeff@racerxfab]

i just wanna know if i can keep my BNR tune/if BNR will be able to add this to their tune and if it will interfere with the plumbing of hard charge tubes (BNR) cause it looks like the TB is in a different spot, but that might just be my sleep deprived brain in action.

You should be able to keep your BNR tune, but it will need to be updated with this addition. The TB location is close to the OEM position but does move slightly, I am not sure of the fitment with the hard pipes. It does work with the OEM charge pipe.

 

[Italianjoe1]

Any capable tuner will be able to adjust for it.

It should run just fine on the stock tune or whatever tune you have for initial install. To optimize for the increased airflow you should always re-tune, but the ECU will adapt to run the target boost and timing even with more flow, assuming your tune is setup that way. I can't see it upsetting fuel trims enough to cause an issue before tuning.

I like this as an option, I know soon I'll have to address the PCV issue, as my sonic will blow it out eventually (nearing 50k now, almost all of it tuned). I don't run a ton of boost but it's not stock. This would be a nice upgrade and a future-proof way to upgrade the PCV system.