SeR_Cyclops
Member
- :
- Mazdaspeed Protege
i agree i think it will look better and also it will give more room when installing it.
505 Intake Manifold COMPLETED!
- Thread starter 505zoom
- Start date
- Status
Thanks for the feedback fellas, keep it coming everyone!
Going back to the round plenum talk, now that it isn't 2AM and I have some extra time to expand on it.
There is no reason to think that a round plenum will flow any better than a square plenum when they both have the same volume in a boosted system. The very first design that we tried in the flow software was round. I was going to take a 4" aluminum sphere that was cut in half and have it welded on to the end of a 4" aluminum tube. I had already dubbed it "The Torpedo", lol.
Using a round plenum would have been, for the most part, the cheapest and easiest way to do it. A piece of round pipe is inexpensive, and needs nothing but an end cap and a TB flange on it to make it work. However, integrating proper velocity stacks into a round plenum bottom is tricky, and the cost benefits are quickly negated due to how complex the machining is on them. Proper velocity stacks were a very high priority for me on this project. I have seen pictures of other manifolds with no velocity stacks or crappy velocity stacks, and I didn't want to put something out that was half-assed like those were (1st gen magnus, for one, along with several others).
After seeing the basic design in round and square in the flow software, I immediately bailed on the round idea in favor of the square. This opened up the door for a better velocity stack design, and an overall better manifold.
Going back to the round plenum talk, now that it isn't 2AM and I have some extra time to expand on it.
There is no reason to think that a round plenum will flow any better than a square plenum when they both have the same volume in a boosted system. The very first design that we tried in the flow software was round. I was going to take a 4" aluminum sphere that was cut in half and have it welded on to the end of a 4" aluminum tube. I had already dubbed it "The Torpedo", lol.
Using a round plenum would have been, for the most part, the cheapest and easiest way to do it. A piece of round pipe is inexpensive, and needs nothing but an end cap and a TB flange on it to make it work. However, integrating proper velocity stacks into a round plenum bottom is tricky, and the cost benefits are quickly negated due to how complex the machining is on them. Proper velocity stacks were a very high priority for me on this project. I have seen pictures of other manifolds with no velocity stacks or crappy velocity stacks, and I didn't want to put something out that was half-assed like those were (1st gen magnus, for one, along with several others).
After seeing the basic design in round and square in the flow software, I immediately bailed on the round idea in favor of the square. This opened up the door for a better velocity stack design, and an overall better manifold.
Oh, and one more thing about the round vs square... you can't get the proper taper needed for across the top of the plenum with a tube. The testing showed that you didn't need a HUGE taper, but a very slight taper was beneficial for even distribution. This was another huge strike in my book for the round tube design.
There is no doubt that a round tube flows better, but it always has to be considered that the gains may not be worth the effort as mentioned.
I think you have done a great job on this, doing everything in your power to make a quality product that will last. The people with enough patience to see the end result will be rewarded. Good things come to those who wait.
Nice work, looking forward to seeing the next mock-up pics of the final shape.(rockon)
I think you have done a great job on this, doing everything in your power to make a quality product that will last. The people with enough patience to see the end result will be rewarded. Good things come to those who wait.
Nice work, looking forward to seeing the next mock-up pics of the final shape.(rockon)
2.0t03speed
Member
- :
- 08.5 CWP Speed 3
o one thing i forgot to mention and ill step in and say this before rich,but the price is going to go up with this new design. Because there are more cuts and more welds that have to be done now. So i just figured id give yall a heads up so your not suprised. The price isnt going to go up alot but it is going to go up.
You could still make that taper with a round plenum.
Put a thick slit down the length of it, pinch it together, weld.
And then the velocity stack machining turns into an even bigger nightmare, haha.
I hear ya there, but I was just making a point.
The new design is the cleanest and most well thought out design of the three. Rich I'm glad you were able to have someone else help out since Kelly is slammed with work. I'm so confident that this will be the key to making some serious horsepower with my turbo kit. I have faith in Rich's skills and his design, props to him for attempting and now following through with a much needed "badass" intake manifold for the msp!! The protege aftermarket is very limited as you all know, I'm so grateful that us protege guys are able to acquire great parts. Vote 505zoom for merchant member of the year, if there is such a thing he should win.
(bump)
(bump)
SeR_Cyclops
Member
- :
- Mazdaspeed Protege
lol we should get atonie on this one!
Revised mockup will be in my hands tomorrow! If everything fits without any issues, I am taking it right back to the machine shop to have the brackets, vac-block, and injector holes all wrapped up. If all goes well, I hope to have the complete proto installed on my car this weekend or very early next week. (rockon)
yellowmsp035
Member
- :
- Yellow 2003.5 MSP
wow thats awesome!!! congrats and thanks again
2.0t03speed
Member
- :
- 08.5 CWP Speed 3
good job your on top of things like always
SeR_Cyclops
Member
- :
- Mazdaspeed Protege
man i you will have to show us some pic's, as soon as you get it in your hands.
<---------excited!
2.0t03speed
Member
- :
- 08.5 CWP Speed 3
kellys on the way to richs house standby for updates
- Status
