interest in my new custom intake manifold for gti-r
Hi all guys,
As you know I have been working on a custom intake manifold for the Pulsar gti-r.
The first prototype is being fitted this week, but meanwhile, we have been working on a new design , and have improved a lot of big and small details.
The new manifold is a totally new concept and is really well engineered. Some of you will notice the similarities with the Australian made Hypertune manifolds.
It will be built in 3 main parts:
- Runners
- Plenum
- Head flange
The only part that will have welds on it is the plenum as the runners will be fitted to the plenum and to the head flange by screws ( 5x5mm screws to secure the runners to the head flange and 4x5mm screws to secure the runner to the plenum).
The injector port will be machined directly on the runner, so no nasty welds and perfect location for the injector.
Runners’ length has been increased to a total of 135mm and features raised velocity stacks for improved flow.
Perfect seal between the runners and head flange/plenum, will be granted by 3mm o-rings. Size and depth of o-ring locating groove have been precisely calculated in order to have the correct o-ring preload.
Being built in separate parts, it will allow us to change the shape size of the plenum without having to change or modify the manifold. So it will be available in tapered and non tapered design.
Like always, the plenum will be fully polished and flanges skimmed for a perfect seal.
The runner is a very difficult part to realize and needs a 4 axis CNC machine center to be realized. That is why I had to send enquiries to several companies all over the world. I contacted companies in USA, Hong Hong, China, Italy and Australia.
I have received crazy high quotes from some companies, while other are suggesting a production method that is not cost effective for small production lots.
As you can imagine, the cost of the runners always depends on the quantity.
The highest quote so far will bring the cost of the full manifold at around 1200$. This is based on a quote received by a leading company in USA .This price is high I know, but is always cheaper than was I had been quoted by O2 induction and is still cheaper than the Hipertune manifold. This is valid only if we can order 6 or more manifolds.
However we have chances to bring cost down a lot, as I have received a really interesting quote from another company. In that case, cost should be of around 850$.Awesome price considering the high level of this product.
It takes a lot of time to project, find contacts, send requests etc, so this is the last time I involve myself in this kind of project.
If there is not enough interest, I will discard the project and only have one unit made.
Manifold spec:
- CNC machined runners, with integrated injector ports, double o-rings,fully machined to 0.05mm tolerance
- 10mm thick, laser cut, head flange
- 10 mm thick TB flange
- Plenum constructed by 3 and 6mm thick aluminium, fully polished and TIG welded. Plenum base is 6mm thick, as the runners will bolt right there.
- Chance to choose plenum shape (tapered or non tapered)
- 6061 alloy construction for the entire manifold
As you know I have been working on a custom intake manifold for the Pulsar gti-r.
The first prototype is being fitted this week, but meanwhile, we have been working on a new design , and have improved a lot of big and small details.
The new manifold is a totally new concept and is really well engineered. Some of you will notice the similarities with the Australian made Hypertune manifolds.
It will be built in 3 main parts:
- Runners
- Plenum
- Head flange
The only part that will have welds on it is the plenum as the runners will be fitted to the plenum and to the head flange by screws ( 5x5mm screws to secure the runners to the head flange and 4x5mm screws to secure the runner to the plenum).
The injector port will be machined directly on the runner, so no nasty welds and perfect location for the injector.
Runners’ length has been increased to a total of 135mm and features raised velocity stacks for improved flow.
Perfect seal between the runners and head flange/plenum, will be granted by 3mm o-rings. Size and depth of o-ring locating groove have been precisely calculated in order to have the correct o-ring preload.
Being built in separate parts, it will allow us to change the shape size of the plenum without having to change or modify the manifold. So it will be available in tapered and non tapered design.
Like always, the plenum will be fully polished and flanges skimmed for a perfect seal.
The runner is a very difficult part to realize and needs a 4 axis CNC machine center to be realized. That is why I had to send enquiries to several companies all over the world. I contacted companies in USA, Hong Hong, China, Italy and Australia.
I have received crazy high quotes from some companies, while other are suggesting a production method that is not cost effective for small production lots.
As you can imagine, the cost of the runners always depends on the quantity.
The highest quote so far will bring the cost of the full manifold at around 1200$. This is based on a quote received by a leading company in USA .This price is high I know, but is always cheaper than was I had been quoted by O2 induction and is still cheaper than the Hipertune manifold. This is valid only if we can order 6 or more manifolds.
However we have chances to bring cost down a lot, as I have received a really interesting quote from another company. In that case, cost should be of around 850$.Awesome price considering the high level of this product.
It takes a lot of time to project, find contacts, send requests etc, so this is the last time I involve myself in this kind of project.
If there is not enough interest, I will discard the project and only have one unit made.
Manifold spec:
- CNC machined runners, with integrated injector ports, double o-rings,fully machined to 0.05mm tolerance
- 10mm thick, laser cut, head flange
- 10 mm thick TB flange
- Plenum constructed by 3 and 6mm thick aluminium, fully polished and TIG welded. Plenum base is 6mm thick, as the runners will bolt right there.
- Chance to choose plenum shape (tapered or non tapered)
- 6061 alloy construction for the entire manifold
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