John Slade wrote:

Yes. I'd appreciate some input on building the intake too. I

just got my

manifold. It looks good and its a great start, but the flange

is too small

and two of the bolt holes miss it. ('93 13B REW). How do I

get around that?

Weld a plate on the edge? Paul mentions "bell mouths", but

the ends of the

runners are square and flat. Should we fabricate these bells

or buy them -

any sources? Also, for those who've removed metal with a die

grinder - any

tricks on measuring when to stop?
John Slade
Cozy IV 13B Turbo

Since you are doing a turbo don't forget the intercooler.

Very important

to prevent detonation. Install an intake manifold temp sensor after
the intercooler and don't let the temp get much above about

140 degrees

F.

Here is the design I intend to use on the KIS. It uses a custom
intercooler core from Spearco. One of these days I will get around
to doing a 3D rendering on this design.

If you don't want to do this you
could use an off the shelf intercooler, mount it elsewhere  and make
the plenum a simple square tube about three by three inches or
larger. Connect
it by at least 2.5 inch or 2.75 inch hose or pipe to the intercooler.
You can weld the flat parts of the runners together to form one
wall of the plenum.

The plenum will need to be fabricated out of at least .065 wall
6061 T6 aluminum to withstand the turbo pressure. You might luck out
and find some 3 inch square rectangular extrusion. It is amazing what
ten psi can do to a sheet metal box.

Paul Lamar

If I weld the flat ends of the runners together I wont have bells in
the plenum.

I don't follow you John. Why not? Cut them to look like this
and weld them together along the edges. You did get this picture
did you not?

Are the bells more important for NA?

They increase the flow in any fluid system.
If anybody (even you Finn :)) wants an education on bell mouths
just put the
the key words "fluid flow bell mouth" in www.google.com
Here too is a picture of the bell mouths Jim Mederer used on his
900 HP turbo 3 rotor.

I have the stock intercooler, but havent found a home for it yet.
The diagrams are a little hard to follow.

I am not the best draftsman in the world but they should be no problem if
you are used to reading mechanical drawings.
Admittedly a 3D rendering would be easier to visualize for those not used
to mechanical drawings.

I dont see the throttle body.
I would expect it to go between the intercooler and the plenum. Right?
John Slade

No. The throttle goes between the the turbo and the intercooler in this
design. Not shown in the drawings. In fact I intend to use a
slide throttle
mounted on the firewall with a simple push pull rod.  That won't
work for you of
course as you have a pusher. In theory slide throttles, unlike
butterflies, suffer
no pressure loss when wide open.

If you use a separate intercooler you can place the throttle between
the intercooler and the plenum if you wish. My method simplifies
and reduces
the air plumbing required.

Paul said:

I don't follow you John. Why not? Cut them to look like this...

Well, yes. there is a 1/2 inch of curve there. I thought a much bigger bell
was called for. I seem to remember a 3D drawing that showed what looked like
trumpets inside the plenum.

At one time we uploaded a 3D with the bells extended but 
the radius of the bells was exactly the same. As I said we changed 
by moving the bells back inside the runners to make it less costly 
to machine,

Paul Lamar
 
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