tooter's manifold adventure... - Page 14 - Toyota Yaris Forums

tooter · 07-15-2012, 08:11 PM

Quote:

Originally Posted by XFACOR

Will be interesting to see how it comes out. Mine took 18hrs to fabricate with CNC time.

Wow... 18 hours.

Those elongated velocity stacks are fabulous pieces of machining! I love seeing stuff like that. They're like precious works of art. Sophisticated parts like that would take a whole lot longer being hand drilled and milled from scratch.

CNC design and execution is a beautiful combination of technology and artistry.

I have absolutely no idea how long the flange will take. But it is it's pretty simple by comparison. We're only doing one to see how it will work out. They're working on the throttle body adaptor right now, but I can go ahead and get the manifold welded up and test fit on the engine next week as the TB adaptor simply bolts on as a retrofit item.

XFACOR · 07-15-2012, 08:37 PM

The runners were the most time consuming. We used oval bar stock and then split it down the center and hand fabricated them to go from the smaller dia. head flange to our much larger CNC oval velocity stack. We use no round to oval or square tubing of any kind. The plenum is CNC D-Shaped and angle tappered for the T/B. And lastly we machined our billet bungs for the direct port nitrous.

All and all I'm very happy with the out come. I saved 5ft. of turbo piping by swithcing to right-hand side T/B mount and improved overall flow of this unique system.

Viperoni · 07-16-2012, 12:10 AM

Quote:

Originally Posted by XFACOR

The runners were the most time consuming. We used oval bar stock and then split it down the center and hand fabricated them to go from the smaller dia. head flange to our much larger CNC oval velocity stack. We use no round to oval or square tubing of any kind. The plenum is CNC D-Shaped and angle tappered for the T/B. And lastly we machined our billet bungs for the direct port nitrous.

All and all I'm very happy with the out come. I saved 5ft. of turbo piping by swithcing to right-hand side T/B mount and improved overall flow of this unique system.

It sure looks good, can't wait to see that motor in action :)

Good stuff to tooter too, I can't wait to see the IM welded to the flange and sitting on a 1NZ :D

tooter · 07-16-2012, 12:40 AM

If I can find enough time off work, it'll happen this coming week.

tooter · 07-16-2012, 12:52 AM

I noticed you used a thick flange...

Everything hanging off of the front of the engine kind of freaked me out so I did like you did and also designed the flange to be thick (one inch), even though the manifold is quite lightweight. When I pick up everything from the shop, I'm curious to weigh it against the stock intake just to see how much difference there is.

XFACOR · 07-16-2012, 09:28 AM

3/4 to 1" is generally the rule of thumb when using a aluminum flage. Welding aluminum gets very hot so you don't want any deflection or warping. Best to set it in a jig of some kind.

I always use 1" on intake manifold.

tooter · 07-16-2012, 11:36 AM

The CNC guys told me that aluminium stock has surface stresses from being formed, so they're milling both large surfaces a few thousandths to remove the more highly compressed material to further reduce the chance of warping during the intense localized heat of welding. Grooving to accept the stock Orings will go a long way to insure a leak free seal, because if that works for an easily deformable OEM plastic manifold, it should work great on aluminium.

This is actually a very simple project, but is a completely new experience for a total novice like me. I have to say that this has been so much fun

working out each little design detail to do my very best to cover all the bases before the actual prototype is machined.

Can't wait 'til tomorrow...

XFACOR · 07-16-2012, 11:50 AM

Your project is coming nicely Tooter. I'm sure your excited to see how it turns out. And even more excited to see how it looks in the engine bay!

tooter · 07-16-2012, 11:55 AM

I'm pretty sure that the manifold's bling will exceed its performance.

XFACOR · 07-16-2012, 12:09 PM

you never know bro.

malibuguy · 07-16-2012, 02:52 PM

i used to weld intake manifolds like whats on TBRs car, but for 2JZs & 2RZs...the head flange, runners & plenum baseplate had to be tightly placed/sammiched in a jig...3/8" thick steel plates on either side with 1/2" thick all thread bolted thru each runner.

With alternating welds on each runner, I would get virtually no warpage at all...requiring at most the slightest kiss on a belt sander to true it up

of course with the 'rolla intake...you cant use a jig like that

tooter · 07-17-2012, 08:55 PM

We talked about the welding issues today...

...while the flange was being made...

There's more pics and lots of video that I'll be uploading time permitting.

Golddeenoh · 07-17-2012, 09:51 PM

shinny

tooter · 07-18-2012, 09:40 AM

The flange and throttle body adaptor will both be ready to pick up on Thursday. (goody

)

Here's a video of the CNC machine making the flange...

http://www.youtube.com/watch?v=yVkFs7PlMVc

This is so exciting to watch the part being made!

Those numbers flowing down the lcd screen are the running stream of thousands of X and Y coordinates which locate the milling bit which is accurate to .0005 inch and can exert force of up to 2,000 pounds. The load graphs show minimal total spindle loading of about 3%. The part takes about 4 hours to manufacture. I'm going to try to get the parts to the welder as quickly as possible, and may have the manifold on the engine this weekend.

Bluevitz-rs · 07-18-2012, 10:14 AM

^Your link is bad... It just brought me to my OWN youtube video page.

tooter · 07-18-2012, 10:34 AM

Try it now. The link is outside of my account.

malibuguy · 07-18-2012, 11:33 AM

awesome

Bluevitz-rs · 07-18-2012, 11:48 AM

Cool. I miss my tool and die days sometimes. Took it in school and never found a job that would pay a decent wage.

07-16-2012, 02:52 PM	#245
malibuguy Obsessed with 1.5L Drives: '10 PW Yaris Sedan Join Date: Feb 2011 Location: Westminster, MD Posts: 907	i used to weld intake manifolds like whats on TBRs car, but for 2JZs & 2RZs...the head flange, runners & plenum baseplate had to be tightly placed/sammiched in a jig...3/8" thick steel plates on either side with 1/2" thick all thread bolted thru each runner. With alternating welds on each runner, I would get virtually no warpage at all...requiring at most the slightest kiss on a belt sander to true it up of course with the 'rolla intake...you cant use a jig like that __________________ -Greg...the Exhaust Freak. -10 PW sedan 107whp/110wtq, full exhaust, suspension bits, TRD LSD -06 Highlander 3mzfe Limited AWD -82 Malibu, 1uzfe swap -97 Tercel coupe, 1nzfe/4.31 -96 Tercel coupe, Turbo 5efe, autoX -96 Tercel 4dr

07-17-2012, 09:51 PM	#247
Golddeenoh Takes corners too fast! View User's Garage Drives: Absolute Red 2009 Yaris HB Join Date: Apr 2012 Location: Columbia, SC Posts: 830	shinny __________________ mods:15''Drag DR21 w/Nitto NeoGen 205/50R15, Tanabe DF210 lowering springs 1.6/1.8, TRD Rear Sway Bar, Tanabe Front Sway Bar, Micro Image Short Throw Shift Kit (both in and under), 8.64lbs flywheel, F1 Stage 4 Clutch, AEM Cold Air Intake (Red), Megan Racing Header, DC Sports Axle Back Exhaust, Micro Image Crank Pulley, NST lite Alternator Pulley, ARP Manifold Stud Kit,Tanabe Front Strut Tower Brace, ScanGuage II, Micro Image Silicone Radiator Hose Kit (Red), NRG Carbon Fiber Shift Knob (round), 2009-2011 Toyota Yaris Liftback Foglight kit, NRG Grounding Kit (Red), Hella Horns(Red),CF Hood

07-18-2012, 09:40 AM	#248
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	The flange and throttle body adaptor will both be ready to pick up on Thursday. (goody) Here's a video of the CNC machine making the flange... http://www.youtube.com/watch?v=yVkFs7PlMVc This is so exciting to watch the part being made! Those numbers flowing down the lcd screen are the running stream of thousands of X and Y coordinates which locate the milling bit which is accurate to .0005 inch and can exert force of up to 2,000 pounds. The load graphs show minimal total spindle loading of about 3%. The part takes about 4 hours to manufacture. I'm going to try to get the parts to the welder as quickly as possible, and may have the manifold on the engine this weekend. Last edited by tooter; 07-18-2012 at 10:32 AM.

07-18-2012, 11:33 AM	#251
malibuguy Obsessed with 1.5L Drives: '10 PW Yaris Sedan Join Date: Feb 2011 Location: Westminster, MD Posts: 907	awesome __________________ -Greg...the Exhaust Freak. -10 PW sedan 107whp/110wtq, full exhaust, suspension bits, TRD LSD -06 Highlander 3mzfe Limited AWD -82 Malibu, 1uzfe swap -97 Tercel coupe, 1nzfe/4.31 -96 Tercel coupe, Turbo 5efe, autoX -96 Tercel 4dr

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07-15-2012, 08:37 PM	#236
XFACOR Banned Drives: 1nz-fe Join Date: Jul 2012 Location: FL Posts: 19	The runners were the most time consuming. We used oval bar stock and then split it down the center and hand fabricated them to go from the smaller dia. head flange to our much larger CNC oval velocity stack. We use no round to oval or square tubing of any kind. The plenum is CNC D-Shaped and angle tappered for the T/B. And lastly we machined our billet bungs for the direct port nitrous. All and all I'm very happy with the out come. I saved 5ft. of turbo piping by swithcing to right-hand side T/B mount and improved overall flow of this unique system.

07-16-2012, 12:40 AM	#238
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	If I can find enough time off work, it'll happen this coming week.

07-16-2012, 12:52 AM	#239
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	I noticed you used a thick flange... Everything hanging off of the front of the engine kind of freaked me out so I did like you did and also designed the flange to be thick (one inch), even though the manifold is quite lightweight. When I pick up everything from the shop, I'm curious to weigh it against the stock intake just to see how much difference there is.

07-16-2012, 09:28 AM	#240
XFACOR Banned Drives: 1nz-fe Join Date: Jul 2012 Location: FL Posts: 19	3/4 to 1" is generally the rule of thumb when using a aluminum flage. Welding aluminum gets very hot so you don't want any deflection or warping. Best to set it in a jig of some kind. I always use 1" on intake manifold.

07-16-2012, 11:36 AM	#241
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	The CNC guys told me that aluminium stock has surface stresses from being formed, so they're milling both large surfaces a few thousandths to remove the more highly compressed material to further reduce the chance of warping during the intense localized heat of welding. Grooving to accept the stock Orings will go a long way to insure a leak free seal, because if that works for an easily deformable OEM plastic manifold, it should work great on aluminium. This is actually a very simple project, but is a completely new experience for a total novice like me. I have to say that this has been so much fun working out each little design detail to do my very best to cover all the bases before the actual prototype is machined. Can't wait 'til tomorrow...

07-16-2012, 11:50 AM	#242
XFACOR Banned Drives: 1nz-fe Join Date: Jul 2012 Location: FL Posts: 19	Your project is coming nicely Tooter. I'm sure your excited to see how it turns out. And even more excited to see how it looks in the engine bay!

07-16-2012, 11:55 AM	#243
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	I'm pretty sure that the manifold's bling will exceed its performance.

07-16-2012, 12:09 PM	#244
XFACOR Banned Drives: 1nz-fe Join Date: Jul 2012 Location: FL Posts: 19	you never know bro.

07-17-2012, 08:55 PM	#246
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	We talked about the welding issues today... ...while the flange was being made... There's more pics and lots of video that I'll be uploading time permitting.

07-18-2012, 10:14 AM	#249
Bluevitz-rs 1NZ-6spd View User's Garage Drives: '05 6-Spd Vitz RS Join Date: Oct 2008 Location: Oshawa, Ontario, Canada Posts: 2,967	^Your link is bad... It just brought me to my OWN youtube video page.

07-18-2012, 10:34 AM	#250
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	Try it now. The link is outside of my account.

07-18-2012, 11:48 AM	#252
Bluevitz-rs 1NZ-6spd View User's Garage Drives: '05 6-Spd Vitz RS Join Date: Oct 2008 Location: Oshawa, Ontario, Canada Posts: 2,967	Cool. I miss my tool and die days sometimes. Took it in school and never found a job that would pay a decent wage.