My prototype Intake manifold (update 2/18/06) - Focaljet

**CHIBULLSAN** · 12-18-2005, 11:14 PM

From design to raw materials, to finished product. I will try to post more updates on what I have begun to build. This is an all aluminum intake manifold with a large manifold, 4 runners - shown attached to the large manifold, 4 throttle bodies with injector boss - yet to be machined from the large chunks of aluminum, and a head flange - yet to be machined from the really large chunk there! Every piece on the manifold will be raw material and made from scratch including the throttle plates, throttle shaft and linkage. Of course Ill buy the bearings, springs, and screws, but thats it. The tubes will be welded in, but for the most part the rest will be bolted and sealed with Orings. Tell me what you think. Ask questions! i just wanted to share.

I added this pic 12/22/05 - shows the completed flange to hold the runners to the plenum. This will be welded up this weekend and have new pics next week.. I am also starting to cut the throttle bodies this weekend, and possibly start the throttle plate shaft.

Added 12/23/05 - I finished the program for the first Throttle body, I finished the top side, I need to do 3 more sides, and the top for the injector. So far 1 down and a few minor adjustments in the program to get the time faster. But here are a few shots.

A pretty cool shot of the coolant and chips flying ... well they are in there, just so much coolant!

Some mock up of the throttle plate inside to see what it would look like.

12/27/06 - after a few hours of machining and welding, we have a good idea what everything will look like and size wise will fit. Here are a few pics of the ITB's bolted to the welded manifold. We will have the shaft and TB's finished this week, and the head flange will possibly started this upcoming weekend.

01/24/06 - a couple more hours last night and I have the bearings all inplace in the TB's and the Delrin races are in place inside as well. The Flange on the plenum was milled flat and now fits the TB's perfectly. The shaft was finished to accept the TB plates, and they are all secured in place. I still need to work out the linkage next.

01/29/06 - Another long day and here are the results....

02/08/06 - A few hours more and here is the head flange attached to the ITB's. Itll take alittle time, but Ill need to adjust each plate and each TB so that each one seals perfectly. Its close, but not good enough yet. ill have more when I can get to the mock up motor, and show the whole thing assembled and installed on it with the alternator bracket I have been working on.

02/18/06 - Some time has passed and a new addition is added here. I have here a idle control manifold that will be welded to the major diameter of the manifold. It will have 4 individual tubes leading to the other side of the throttle plate. I will also be showing the fuel rail mounted and the alternator mounting bracket. These are done, just no pics yet.

02/19/06 - Got alot more done. I need to finish the linkage, but I think I got a good grasp on what i want to do. I still need to weld the IAT manifold, and the vacume manifold that is not shown yet and the end caps on the end of the manifold. The TB's need final fitting, and the alternator does too. We are getting very close here to completion.

**installman** · 12-18-2005, 11:16 PM

very cool!!

**meowmix123** · 12-18-2005, 11:41 PM

nice! gonna be great for power and response with the itbs

**LT1s10** · 12-18-2005, 11:51 PM

keep us posted on how it works over stock
Is this for a zetech or a SPI?

**CHIBULLSAN** · 12-18-2005, 11:53 PM

Quote:

Originally Posted by LT1s10

keep us posted on how it works over stock
Is this for a zetech or a SPI?

Its going on my Turbocharged SVT.

**Broke_Two_Foci** · 12-18-2005, 11:58 PM

sweet so it should bolt up to a zetec too. so if you get that working well are you going to start producing them? looks great. shoud be great for forced induction.

**focusownerskid** · 12-19-2005, 12:05 AM

No more blower?

- Drew

**CHIBULLSAN** · 12-19-2005, 12:09 AM

Quote:

Originally Posted by focusownerskid

No more blower?

- Drew

Well the twincharge setup worked. But I screwed up and over spun the supercharger. Too hot, blah blah. Anyways, I had done everything i wanted to with that setup, so I wanted to try something new, again. So now Im turbo T3/T4 going for 300 - 350whp, and thats that. But right now, Im looking for things that will give it that extra edge over everyone else out there. ITB's was the best solution. Even better was I got to make something else for my car! Haha. I expect very noticable and signifigant gains over any other manifold.

**Evan_Murphy** · 12-19-2005, 07:57 AM

make me one? =)

**OrangeSVT03** · 12-19-2005, 07:58 AM

That sorta looks like the stage 2 manifold Tom is working on. Yours still looks good......

Personally I think the ITB's will look good.... but I dont know about their performance.

One question....

Why use ITB's on a log style intake, wouldn't they do better with individual runners?

Regaurdless... it still looks cool

**Honda Hunter** · 12-19-2005, 10:30 AM

Quote:

Originally Posted by focusownerskid

No more blower?

- Drew

Good move!

**Honda Hunter** · 12-19-2005, 10:32 AM

It's so cool to see custom jobs like this.

I can't wait to see some photos of the more detailed pieces once you get into the throttle plate assemblies.

**CHIBULLSAN** · 12-19-2005, 10:47 AM

Quote:

Originally Posted by OrangeSVT03

That sorta looks like the stage 2 manifold Tom is working on. Yours still looks good......

Personally I think the ITB's will look good.... but I dont know about their performance.

One question....

Why use ITB's on a log style intake, wouldn't they do better with individual runners?

Regaurdless... it still looks cool

I didnt know Tom had a manifold he was making.

Individual runners are for an openair style, or non MAF. I want my MAF. Besides the engine still needs to pull air from somewhere. If your pulling it from a runner in a MAF setup, then the engine has to work X amount harder to get the air it needs from a further distance. With a large volume of air readily avalible from the throttle bodies directly on the head, the engine will have very fast response, and as much air as it needs. I kinda copied the basic style from the Ferrari engines I saw when I went to the factory last month in Modena, Italy. They have a huge air box surrounding the throttle bodies that are directly above the valve opening.

**OrangeSVT03** · 12-19-2005, 10:51 AM

Toms is just a one off for me....

it just seems that with a turbo force feeding the engine a single large TB would work and simplify things.

On the other hand it would look near as good.

**CHIBULLSAN** · 12-19-2005, 10:56 AM

Quote:

Originally Posted by OrangeSVT03

it just seems that with a turbo force feeding the engine a single large TB would work and simplify things.

True ... BUT, the engine isnt being force fed from 750rpm - 3500rpm. Alot of driving you want more response and better torque in that area.

**CHIBULLSAN** · 12-19-2005, 12:22 PM

Here is a closer view of the 3D model. It shows alot, its exactly what the finished product will look like, minus the random colors. I blanked out the 2 ITB's to see the shaft and plates. There is one more flange that the ITB's bolt to that bolts to the head, this flange will have the transfer from the 2" Dia runners to the oval type shape the head is. Just thought Id share.

**02_smurf** · 12-19-2005, 12:31 PM

just amazing... I want fabbing skills.

**BUR_ZX3** · 12-19-2005, 12:50 PM

Hottness!

**DJuanHouston** · 12-19-2005, 01:14 PM

nice tools, I need that setup. Are these TB's going to need to be syncronized like my bike?

**CHIBULLSAN** · 12-19-2005, 01:17 PM

Quote:

Originally Posted by DJuanHouston

nice tools, I need that setup. Are these TB's going to need to be syncronized like my bike?

Yes exactly like it. I was actually going to buy a GSX or similar manifold to copy from, or better yet, use, but they were too small.

**buzzbomb** · 12-19-2005, 01:42 PM

You are a sick sick man, and you need a real hobby...

Also, I want one.

Is it me, or does the plenum look like a fartcan? Now we can have one on each side of the engine! w00t!

**belacyrf** · 12-19-2005, 02:10 PM

Quote:

Originally Posted by CHIBULLSAN

Its going on my Turbocharged SVT.

Turbocharged only??? What happen to the other piece???

I can't wait to hear what you think about this an the performance it gives!

**BUR_ZX3** · 12-19-2005, 02:25 PM

Quote:

Originally Posted by belacyrf

Turbocharged only??? What happen to the other piece???

Quote:

Originally Posted by chibullsan

Well the twincharge setup worked. But I screwed up and over spun the supercharger. Too hot, blah blah. Anyways, I had done everything i wanted to with that setup, so I wanted to try something new, again.

This is a start in the right direction!

**Torque** · 12-19-2005, 05:27 PM

This looks bitchin', for sure.

I have no doubt that the throttle response and other benefits of the ITB's will add some real "character" to your engine!

Great job. To be honest, I find this much more impressive and practical than the dual-charging set up.

Is that Inventor that you are using for the plans?

12-18-2005, 11:14 PM	#1
CHIBULLSAN Senior TEAM Member Join Date: Apr 2002 Location: (Aaron) Pittsburgh, Pa Posts: 1,677	My prototype Intake manifold (update 2/18/06) From design to raw materials, to finished product. I will try to post more updates on what I have begun to build. This is an all aluminum intake manifold with a large manifold, 4 runners - shown attached to the large manifold, 4 throttle bodies with injector boss - yet to be machined from the large chunks of aluminum, and a head flange - yet to be machined from the really large chunk there! Every piece on the manifold will be raw material and made from scratch including the throttle plates, throttle shaft and linkage. Of course Ill buy the bearings, springs, and screws, but thats it. The tubes will be welded in, but for the most part the rest will be bolted and sealed with Orings. Tell me what you think. Ask questions! i just wanted to share. I added this pic 12/22/05 - shows the completed flange to hold the runners to the plenum. This will be welded up this weekend and have new pics next week.. I am also starting to cut the throttle bodies this weekend, and possibly start the throttle plate shaft. Added 12/23/05 - I finished the program for the first Throttle body, I finished the top side, I need to do 3 more sides, and the top for the injector. So far 1 down and a few minor adjustments in the program to get the time faster. But here are a few shots. A pretty cool shot of the coolant and chips flying ... well they are in there, just so much coolant! Some mock up of the throttle plate inside to see what it would look like. 12/27/06 - after a few hours of machining and welding, we have a good idea what everything will look like and size wise will fit. Here are a few pics of the ITB's bolted to the welded manifold. We will have the shaft and TB's finished this week, and the head flange will possibly started this upcoming weekend. 01/24/06 - a couple more hours last night and I have the bearings all inplace in the TB's and the Delrin races are in place inside as well. The Flange on the plenum was milled flat and now fits the TB's perfectly. The shaft was finished to accept the TB plates, and they are all secured in place. I still need to work out the linkage next. 01/29/06 - Another long day and here are the results.... 02/08/06 - A few hours more and here is the head flange attached to the ITB's. Itll take alittle time, but Ill need to adjust each plate and each TB so that each one seals perfectly. Its close, but not good enough yet. ill have more when I can get to the mock up motor, and show the whole thing assembled and installed on it with the alternator bracket I have been working on. 02/18/06 - Some time has passed and a new addition is added here. I have here a idle control manifold that will be welded to the major diameter of the manifold. It will have 4 individual tubes leading to the other side of the throttle plate. I will also be showing the fuel rail mounted and the alternator mounting bracket. These are done, just no pics yet. 02/19/06 - Got alot more done. I need to finish the linkage, but I think I got a good grasp on what i want to do. I still need to weld the IAT manifold, and the vacume manifold that is not shown yet and the end caps on the end of the manifold. The TB's need final fitting, and the alternator does too. We are getting very close here to completion. Last edited by CHIBULLSAN : 02-19-2006 at 07:53 PM.

12-18-2005, 11:16 PM	#2
installman TEAM Member Join Date: May 2002 Location: Kelowna, BC Posts: 287	Re: My prototype Intake manifold + very cool!! __________________ sometimes you just gotta say "what the F&*$" Too many mods to list!

12-18-2005, 11:41 PM	#3
meowmix123 TEAM Member Join Date: Dec 2005 Posts: 125	Re: My prototype Intake manifold + nice! gonna be great for power and response with the itbs

12-18-2005, 11:51 PM	#4
LT1s10 TEAM Member Join Date: Nov 2005 Posts: 355	Re: My prototype Intake manifold + keep us posted on how it works over stock Is this for a zetech or a SPI? __________________ 2000 Focus SE SPI, LEMON FIXED AND REPAIRED DAILY 57 3200 pickup 454, TH400, 9" 97 Dodge 4x4 318

12-18-2005, 11:58 PM	#6
Broke_Two_Foci Senior TEAM Member Join Date: Jan 2005 Location: C.F.H. Posts: 3,682	Re: My prototype Intake manifold + sweet so it should bolt up to a zetec too. so if you get that working well are you going to start producing them? looks great. shoud be great for forced induction. __________________ Aerodynamics are for people who cannot build engines A Chevy tried to kill me, and my focus paid the ultimate price. Dezert Focus ; JCM Racing Crew Chief ; 100,000 mile club, Memorial For My Zx3

12-19-2005, 12:05 AM	#7
focusownerskid Administrator Join Date: Aug 2000 Location: Monroe, MI Posts: 15,448	Re: My prototype Intake manifold + No more blower? - Drew __________________ '02.5 SVTF - For Sale; http://forums.focaljet.com/vehicles-...svt-focus.html '01 Turbo ZX3 - For Sale; http://forums.focaljet.com/vehicles-...ml#post6770262 type dRew & friends Motorsports.

12-19-2005, 07:57 AM	#9
Evan_Murphy TEAM Member Join Date: Jul 2003 Location: Manasquan NJ Posts: 803	Re: My prototype Intake manifold + make me one? =) __________________ Fo·cused, v. intr. 3.To concentrate attention or energy 2003 Turbo SVT Focus

12-19-2005, 07:58 AM	#10
OrangeSVT03 Senior TEAM Member Join Date: Apr 2004 Location: Waverly , Ohio Posts: 4,326	Re: My prototype Intake manifold + That sorta looks like the stage 2 manifold Tom is working on. Yours still looks good...... Personally I think the ITB's will look good.... but I dont know about their performance. One question.... Why use ITB's on a log style intake, wouldn't they do better with individual runners? Regaurdless... it still looks cool __________________ 2003 SVT Focus Comp Orange Euro Package #3474 of 3985 Date of Birth July 31, 03 Turbo,Quaife and a bunch of other crap 362whp/316wtq 22PSI on 93 octane......courtesy of Focus-Power and SuperSnailFab

12-19-2005, 10:32 AM	#12
Honda Hunter Senior TEAM Member Join Date: Nov 2001 Location: Fabulous South Florida Posts: 4,855	Re: My prototype Intake manifold + It's so cool to see custom jobs like this. I can't wait to see some photos of the more detailed pieces once you get into the throttle plate assemblies. __________________ -Nick NaRdone

12-19-2005, 10:51 AM	#14
OrangeSVT03 Senior TEAM Member Join Date: Apr 2004 Location: Waverly , Ohio Posts: 4,326	Re: My prototype Intake manifold + Toms is just a one off for me.... it just seems that with a turbo force feeding the engine a single large TB would work and simplify things. On the other hand it would look near as good. __________________ 2003 SVT Focus Comp Orange Euro Package #3474 of 3985 Date of Birth July 31, 03 Turbo,Quaife and a bunch of other crap 362whp/316wtq 22PSI on 93 octane......courtesy of Focus-Power and SuperSnailFab

12-19-2005, 12:22 PM	#16
CHIBULLSAN Senior TEAM Member Join Date: Apr 2002 Location: (Aaron) Pittsburgh, Pa Posts: 1,677	Re: My prototype Intake manifold + Here is a closer view of the 3D model. It shows alot, its exactly what the finished product will look like, minus the random colors. I blanked out the 2 ITB's to see the shaft and plates. There is one more flange that the ITB's bolt to that bolts to the head, this flange will have the transfer from the 2" Dia runners to the oval type shape the head is. Just thought Id share.

12-19-2005, 12:31 PM	#17
02_smurf Moderator Join Date: Oct 2002 Location: With the wemenz: Em or mom Posts: 12,505	Re: My prototype Intake manifold + just amazing... I want fabbing skills. __________________ "I couldn't even get on it, I stabbed myself in the vagina!" -Name withheld to protect the drunkeded

12-19-2005, 12:50 PM	#18
BUR_ZX3 [FJ] Addict Join Date: Apr 2002 Location: On the Set of CSI: Crime Scene Investigation Posts: 35,699	Re: My prototype Intake manifold + Hottness! __________________ Video from the final round of the Focus Challenge... Click Here

12-19-2005, 01:14 PM	#19
DJuanHouston Senior TEAM Member Join Date: Dec 2004 Location: Houston Posts: 1,499	Re: My prototype Intake manifold + nice tools, I need that setup. Are these TB's going to need to be syncronized like my bike? __________________ 02 CDSliver SVT ________________ Steeda Shfiter, VF mounts, Recaro Seats, Magnaflow CatBack, PWSC, Kenwood and JL Audio

12-19-2005, 05:27 PM	#24
Torque Senior TEAM Member Join Date: Aug 2004 Location: ATL Posts: 1,386	Re: My prototype Intake manifold + This looks bitchin', for sure. I have no doubt that the throttle response and other benefits of the ITB's will add some real "character" to your engine! Great job. To be honest, I find this much more impressive and practical than the dual-charging set up. Is that Inventor that you are using for the plans? __________________ http://www.myspace.com/jimmythehoon 1965 Ford F100 (Effie, the stump puller) 1969 1/2 BMW 75/5 (Hoodlum cafe special)

12-19-2005, 05:28 PM	#25
FordFociSHO Senior TEAM Member Join Date: Apr 2001 Location: Minnesota, Darwin Posts: 1,731