Jump to content
SAU Community

Recommended Posts

How to make a complete inlet manifold and plenum from scratch. Pictures tell a thousand words. The end plenum is exactly the same, just the base is a little simple.

All hand made, no cnc machine just a milling machine and a lot of patience and measurements as you can see.

Piece of 10mm aluminium plate

20102007383.jpg

A lot of time measuring and drawing and then approximately 4 hours on a milling machine. Not electronic aids, just by hand

20102007385.jpg

20102007387.jpg

Base and bellmouths cut and ready to go

20102007388.jpg

All in place and tacked together

20102007389.jpg

20102007390.jpg

20102007392.jpg

20102007394.jpg

Sheet of 3mm aluminium

20102007395.jpg

Sheet cut up and engraved

20102007397.jpg

Might as well throw in a throttle body since I have a few "lying" around

20102007396.jpg

And the end result. Polished and blasted ready to deliver.

4G637.jpg

Obviously there is a lot more to it, but you get the idea.

For example

designing of plenum to not only fit but do the job.....runner size, diameter, dimensions, length, plenum taper etc etc

matching round bellmouth to a square port

final matching of runners & base once complete welded

machining the base to ensure a perfectly flat finish

polishing

fitment of vacuum fittings

throttle cable bracket on the bottom of the plenum

make and mount fuel rail

most circumstances, mounting of injector bosses

Your looking at approximately 3-4 days works from design to end product you see above.

More than anything, this will give you an idea of why custom parts (that have been proven) cost so much....and to tell you the thruth my costs are nowhere near what I have seen charged out there. End hourly rate is approx $40 per hour usually less, compared to some workshops charging from $80-120+ per hour it isn't really that bad.

Any questions, please feel free to ask.

Thanks,

Ariel

dam that flange plate is so perfect i thought it was CNC cut

my cnc machinest charges me 20buxs per flange but if he doesnt already have it designed he has to charge me 200buxs just for drawing it up on his computer

it does save time and for 20buxs a flange it works out eazier

for a hand made flange thats realli good, i realli thought i was cnc machined

Edited by STR8E180

he did say it was all done buy hand and no computer controlled.

Which makes it a lot harder and much more tedious to acomplish!

and two still pull that sort of a finish off, man THATS GOLD!!!!!!! :)

love your work!!!!!!!!

please P.M me if you do big orders! :(

Edited by secretgarage

thank you all. when it comes to machining the plate, an obssesive personality does help.

STR8E180 - thanks for the comment, much appreciated. Please pm details of your cnc machinist...thank you

zebra - pm sent on its way

secretgarage - pm sent on its way

benny_blanco - yes they all are. I am actually in the process of building my own flowbench at the moment to help reduce r&d costs.

type vu - Yes, I can do group buys on every plenum I offer.

For the sake of not upsetting moderators - I have already done that too many times - please call me, pm, email or visit my website for any enquiries.

Thanks again for the good feedback.

Ariel

Honestly, it was something I had second thoughts about but considering I will not disclose any measurements/dimensions etc etc, I thought what the hell.

Ariel

still lots of thinking involved to replicate your work, but most who have the means to make this could work that out from scratch anyway.

inspirational though.

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now


  • Similar Content

  • Latest Posts

    • Ye good idea , would have never thought of something like that. Might aswell do it to every pulley and the balancer while I’m there 
    • Use an LS1 or similar, via kit like Frenchy's. But.... It's probably not the alternator. It sounds like belt squeal, which would be because the pulleys are glazed. Rub every groove on the pulleys with 120 grit paper. Report back. Oh, and new belts afterwards too. The old new ones will be shitted up already.
    • Hello all I have 2 r34 sedans , one turbo one na, only recently aquired the na 34.  Man what is with these things.... My turbo 34 started sounding like a super charger, it was screaming at anything above 4000rpm , I took the alternator apart and replaced the front bearing which is the only one I think you can access and it did not fix the issue so presumably the bearing in the rear of the alternator is gone. ( diagnosed it was the alternator by taking off the aux belts one by one to figure out which pulley or bearing it was )  My friend gave me one he had lying around, Installed it , it did not squeal for maybe 500kms and now its started to squeal again briefly on startup  Recently got an na r34 and I replaced the timing belt, water pump + all the auxillirary belts. Runs amazing but it suddenly developed the same squeaking problem but significantly worse, Ive had my neighbour come down screaming at me because it was waking her up everytime I moved the car. It takes a good 2 minutes before it quietens down.  Im yet to diagnose where its coming from but im fairly sure its coming from the alternator aswell. My question isnt about how to fix it but rather where can you get a new alternator for an rb25 neo??? Ive searched everywhere but I havent been able to find a direct fit oem type replacement thats not genuine. All the automotive stores sell an oex one - BXA035 - which I picked up for cheap through a friend with staff discount , got it home only to find the connector is completelty different.... As far as im aware bxa035 is for rb20/30's and after a bit of figuring out the bxa035 has an ev14 type connector, which is tiny compared to the rb25 connector. I actually had an ev14 connector lying around which I was considering just replacing the bigger plug with to get the alternator working but the bxa035 is rated for 70amp vs the rb25 alternators are 90amp ( or so ive been told ? ) That paired along with the fact im about to install an amp + sub in the back and I have the stock sized small battery Im not sure itll do the job unless anyone has another opinion?  I know and have seen all the websites selling the ls1 alternator conversion kit but I am not going down that route, nor do I have the money to. Hopefully I can figure out how to get 2 brand new alternators for both cars. I would buy second hand which there seems to be many of but considering how common this seems to be im sure If I installed a second hand one it would start squealing in no time  Or even better if anyone knows how to fix the issue directly with the alternator itself... Any input appreciated Thank you     Link for bxa035 connector picture
    • As above, replace as many as you can afford. If anything, due to old age.
    • Can confirm previous shop that built my motor had no fking clue about oil control and caused my motor to shit itself after two track days. Current shop, Birrong Automotive, has managed to build me a motor, not to mention, has also let me tune it myself and it has yet to blow up after 7 track days. Great oiling success, yashimash.
×
×
  • Create New...