Composite intake plenum

[DeepSeaDynamo]

So I have been thinking of trying to make an intake manifold plenum out of some type of composite; however, I have no idea what I should use. I seriously doubt the regular bondo resin would hold up to the heat and vibrations from under the hood. My plan is to try and vac bag it around a molded block of Styrofoam.

So what kind of advice can you guys give me?

[Matt93SE]

1. Do more research on composites.
2. Start on something MUCH simpler than an intake manifold.

[Sleepy_Steve]

If you can, talk to someone who has actually made some parts out of composites... Helps you figure out what you'd be getting into; and if you're willing to delve into that.

[Jonty]

I would use carbon as glass/kevlar is not strong enough in a structureal application. But first, as Matt/Steve say start with lots of research first! When you feel ready to begin, start with a flat part like rear 3/4 interior trim pannels or similar to learn how to lay up and make your bag etc... a plenum is waaaaay too difficult to learn with- from my experience start small and simple and then work your way up; if you start on large stuff, even if it is simple you will write off a lot of material in one go which is a very costly way to learn- try to find stuff you can build for $50 not $500 like a hood in carbon and epoxy!

[DeepSeaDynamo]

Thanks for the input guys. I found a great site all about composites and as it turns out the guy who told me "oh yea its not that much harder then 'glassing" was totally full of sh*t. So I guess its time to start practicing welding aluminum.

[VIDAL BABBOON]

A carbon plenum made right will cost thousands and require some very expensive machinery to make correctly.

Learning to TIG weld will cost you a few $ only.

I know what I would go for...

[Sleepy_Steve]

I thought about making one myself a while back for my KA.... I looked at the cost of DIY steel or aluminum intake manifolds, and then looked at the cost of just making a CF plenum.... and both estimates were significantly more than the cost of an Xcessive intake manifold even before factoring in the cost of the learning curve with the new-to-me materials.

I chose to just start saving my pennies.

[DeepSeaDynamo]

yea, my big issue with the xcessive is that the runners are a lot shorter then what I want, I'm not planning on turboing anytime soon, and I don't want to rev super high to get my power. So I was thinking of only getting rid of the 2-3 inches of runner that are attached to the stock plenum and making a larger plenum to bolt onto the stock runners.

[Sleepy_Steve]

Find a buddy with a tig who is willing to try welding up a fairly simple box and then weld it to the upper runners for you.

[True Berserk]

Found this on another forum - http://www.240sxforums.com/forums/ka24de-ka24e/107289-ka24de-intake-manifold-guide.html


Homemade plenum for SR.

http://i136.photobucket.com/albums/q190/warkentinbrothers/2009_0422zealand0582.jpg

http://i136.photobucket.com/albums/q190/warkentinbrothers/2009_0422zealand0580.jpg

[PoorMans180SX]

yea, my big issue with the xcessive is that the runners are a lot shorter then what I want, I'm not planning on turboing anytime soon, and I don't want to rev super high to get my power. So I was thinking of only getting rid of the 2-3 inches of runner that are attached to the stock plenum and making a larger plenum to bolt onto the stock runners.

Get the additional velocity stack plate that bolts in the plenum. It effectively lengthens the runners by a little and helps improve the mid-range a bit.

And I would think the trade off in "low-rpm torque" would be well worth the gains at the top end, even with the stock rev range.

[cdlong]

Something slightly worthwhile out of zilvia.
http://zilvia.net/f/chat/126132-engine-engine-bay-photos-42.html#post4211302
There are some additional pics and details on the next page.

[speed_demon]

Found this on another forum - http://www.240sxforums.com/forums/ka24de-ka24e/107289-ka24de-intake-manifold-guide.html


Homemade plenum for SR.
I love the welds on this manifold. Beautiful.

Now that's how a home made part should look!

[Mark Washington]

http://i945.photobucket.com/albums/ad291/markwashington/powersteerings13005.jpg

I used the xcessive plenum and used the stock flange,made runners.

[240sxTTC]

Here's my Xcessive Manifold with a Q45 TB. It's nice and unclutered compared to the stock one.

https://lh6.googleusercontent.com/-il75j4LOve0/S04fnNi_E7I/AAAAAAAABF4/Oq8821nvkYI/s640/DSC00302.JPG

https://lh6.googleusercontent.com/-nmymQfe4tF8/Te4jzgX9uuI/AAAAAAAABQU/3ZU16cUb8kc/s640/DSC00722.JPG

[KA240SX808]

Found this on another forum - http://www.240sxforums.com/forums/ka24de-ka24e/107289-ka24de-intake-manifold-guide.html




Wow I wrote that a WHILE ago lmao.

Wonder how much power can be seen just from the reduced heat/heat soak from using a Composite Manifold.

[DeepSeaDynamo]

And I would think the trade off in "low-rpm torque" would be well worth the gains at the top end, even with the stock rev range.

well, it really is a trade off, and seeing how I don't track the car yet, and I already have 248/248 cams and pulled the butterflies from the manifold, I don't really wanna loose anymore. I really got to thinking about this whole thing because I'm curious how a longer runner (just a bit shorter then stock) and a much larger plenum (115 - 135% of the displacement of the motor) would do. I was thinking around a 3L plenum, because visually I think about the most I could fit under there would be a 3L bottle.

Mostly I was thinking of trying something new, and seeing how it works out.

Edit: But don't expect anything from me anytime soon, I won't have access to a welder for a while. Oh and a mod can move this to Naturally Aspirated since we have moved away from talking about composites if they want.

[Geno]

Here ya go. Get someone to loan you something like this:
http://airepoweraviation.com/carprogress/Manifold-1.jpg

Then bring it to these guys, done.
http://www.youtube.com/watch?v=ZboxMsSz5Aw

[DeepSeaDynamo]

Can someone sum up whats in the video I'm offshore and the internet is WAY too slow for video to work.

[Bubba]

You give them an item and they have a machine that replicates it in a composite material regardless of size, shape, complexity, or moving parts.
Cool video. Someone send them a plenum and see what it would cost for a couple dozen copies. Haha

[cdlong]

A lot. A plenum is way too simple of a part to bother with 3D printing. I used to work at a company that used it occasionally when we needed to check clearances and whatnot, usually made them in 1/2 or 1/4 scale. It's easier than setting up a casting, but welding plate together requires little setup.

[DeepSeaDynamo]

Oh, thats pretty neat, now I can't wait to check out the video when I get home.