tooter's manifold adventure...

[tooter]

Originally Posted by xnamerxx

No it doesn't hit anywhere.
I'm not sure how it affects the stock cat configuration because I have a custom midpipe, but If I'm guessing you'd need to remove one and move the other. As for the o2 sensors it accepts both in close to the stock location. I chose to do that rather than move the o2 sensors since I have no way of modifying the timing delay for the o2 signal, the downside is I only read half the cylinders.

Sounds like you worked out all the bugs and have a good product with the only obstacle being prohibitive material costs. Maybe in the future something will happen to change that.

[tooter]

Originally Posted by xnamerxx

I chose to do that rather than move the o2 sensors since I have no way of modifying the timing delay for the o2 signal, the downside is I only read half the cylinders.

I wouldn't be too concerned about that, namer.

I just noticed these Doug Thorley headers that are really popular with the Tacoma 4.0 guys only sample one third of the cylinders!

[tooter]

The tooter et is taking shape...





The hole is still a couple of millimeters smaller than the bellmouth so I'll Dremel it for a nice snug fit ready to weld.



This is going to be an effing strange manifold...

Greg

[Flipper_1938]

What does the boob look like on the inside with the flange fitted?

[tooter]

Originally Posted by Flipper_1938

What does the boob look like on the inside with the flange fitted?

It's really close, but bellmouth doesn't quite fit in all the way. I purposefully drilled the hole small as the hole saw does a considerable bit of wandering. This gives me the opportunity to precisely trim the hole for a good fit. I'll post a pic of the inside when I'm done with grinding the opening.

[tooter]

After a couple of hours grinding filing and sanding the bellmouth has a nice snug fit...









The runners remain in direct alignment with the axis of the throttle body bore...






This is the inside of the plenum, there is a complete lack of any flat reflective surfaces. I'll find out what happens then the pulses travel out the mouths of the runners and hit only curved surfaces.

[CrankyOldMan]

So many Freudian themes in this project! I was wondering where the actual seam would be on the bellmouth--for some reason I was thinking you would put it all the way up to the squared shoulders.

[cali yaris]

It looks from the picture, that because of the angle, the throttle body points more directly at two runners, which are slightly further away. See your second picture above. It would be interesting to see a flow test for to see how much each runner is getting.

[tooter]

Originally Posted by CrankyOldMan

So many Freudian themes in this project! I was wondering where the actual seam would be on the bellmouth--for some reason I was thinking you would put it all the way up to the squared shoulders.

That's right, Cranky. I had originally planned for it to drop all the way down to the square corners, but that makes the round part of the bellmouth drop below the contact surface of the hemisphere creating a gap. While the welder could easily fill that gap, I want to try to keep burn through to a minimum by retaining complete contact between the two surfaces so that the inside surface is not compromised.

It took a couple of hours of handwork to get the fit as precise as possible, and I'm totally satisfied with the results.





When I bead blast the whole assembly to normalize all of the surfaces, you'll hardly be able to see the seam even with no welding.

The raised square corners will end up working out nicely as the whole circle of the contact seam is easily accessible to be welded from the outside of the hemisphere. Exploring how to make the best of each detail in the design process is what makes this project no end of fun.

[tooter]

Originally Posted by cali yaris

It looks from the picture, that because of the angle, the throttle body points more directly at two runners, which are slightly further away. See your second picture above. It would be interesting to see a flow test for to see how much each runner is getting.

I know. The offset angled orientation of the throttle body axis in the original plenum was even more offset than the one I'm building. So I softened it slightly. If it wasn't an issue for Toyota, it isn't for me. I think it was done just to get the throttle body pointing slightly upwards to line up with the stock air filter box, so I did the same thing so as to line up with mine.





This is the original manifold throttle body axis orientation.



And this is the tooter et throttle body orientation.



This is why I don't believe that it was ever an issue. First because the flow is so direct, and second the runners are pulling from the plenum That's what I like most about this particular design. It completely eliminates the 90 degree "kink" runner to throttle body axis orientation found in all of the other typical plenum designs.

[jetblast]

Looking ever sooooo smooth!!! Nice!!

[Flipper_1938]

Is it done yet?

[cali yaris]

^ He is currently testing it on Alpha Centauri.

[Astroman]

Originally Posted by Flipper_1938

Is it done yet?

Hey that's the post I see the most on my thread, Something Big is Coming!

[tooter]

Originally Posted by Flipper_1938

Is it done yet?

Not yet.
Right now, the CNC machinist is making a base plate to connect the hemisphere to the intake runners. After that, I make the 3 tubing fittings, everything gets welded up and then I get to drive it.

[tooter]

The machine shop at Origin Designs made two more flanges. Their work is impeccable...



Also got a Corolla manifold to build into another tooter.

[jetblast]

Nothing like billet jewelry.

[tooter]

Here's the CNC machine making tooter intake manifold flanges two at a time...

http://www.youtube.com/watch?v=rh4Ho5tI8KA