Billet and Carbon Fiber Manifold Project

[Natchamp]

Ok, fellow Porsche fanatics, here’s my new project. It’s something I’ve wanted to build for some time now but never could find the time. Since my car has been “down” for measurement taking purposes for months now, I am forced to make time! I’ve started to make the parts and thought I would share my progress. I’ve still got a long way to go put so far everything is going pretty good.

Here is my basic design layout. The manifold will be a complete unit, bolt on, and incorporate individual throttle bodies. Most of the parts will be CNC’d machined and the plenums will be carbon fiber.



Here is a video of the 3D design:

3D Design Video

In order to have all the runners be perfectly cut and accurate in their length and angle, I made a jig.



Here is a video during the making of the jig:
Jig Video1

Here is a video of the jig in use:
Jigg Video2

Here is some work making the plenum prototypes. If all of the measurements work out correctly, I will use these foam parts to make the mold plugs for the carbon fiber parts. Here is what it started out as:



Here are some video's of cutting the plenums:
Plenum1

Plenum2

Plenum3

Plenum4

Here is a video of making the “Y”
Y video

So, as you can see I still have a ton to do but it should be a pretty interesting project. I’ll keep you guys posted. Cheers.

[Jandrews]

I'll be the first to say it.... WWWWWWWOOOOOOWWWWWW!!

Great stuff, Mark. We can always count on you to keep us all on our toes and the edge of our seats!


JA

[Evans, Marv]

What he said, Mark. Fantastic as usual.

[PorscheGuy79]

Sweet Mary mother of...


Frankly, that might be one of the coolest things I have ever seen.

[ScottKelly911]

Awesome project, I'm so jealous. I want it for my car! What engine is this going on? Also, how come you're not doing the entire manifold in CF? I've got an early 964 3.6 with the heavy aluminum Manifold, I wonder how much weight I'd save with a CF unit, or even the plastic unit used from '92 on.

[Nickatnyt]

Dayum. I am looking forward to watching this project continue!

[rfuerst911sc]

Did you stay at a Holiday Inn Express last night??? Nice stuff.

[jhelgesen]

Some guys get all the cool toys.....

[Natchamp]

Thanks guys. Here's some more "in progress" pics.

[emcon5]

That certainly looks very cool, but doesn't the plumbing leading to a single plenum cancel out the benefit of individual throttle bodies?

Tom

[Wrecked944]

Mein Gott in Himmel!

[Natchamp]

Janus, are you calling me names in German ?

Tom, not sure what you mean. The premise for the plenums is to equalize the pressure/flow into the itb's. The plenums should help the itb's, not hinder them.

[Natchamp]

The itb's are integrated into the top plate, inside the plenums. Download the "3D design video" up top and you will see a video of the whole thing. The video even shows the butterflies moving. cheers

[lvporschepilot]

That is the coolest ever. Very Ferrari looking. I bet throttle response is going to be fantastic! Have you calculated a guess to any gains? I wonder what cfm is going to be with that rig. Keep us posted

[RarlyL8]

Nice job Mark. I was wondering if this project would progress.

[ErVikingo]

Awesome ! Man I must write down my ideas for products and see if you can get them made...... Nothing that complex BTW

[arcsine]

[emcon5]

Originally posted by Natchamp
Janus, are you calling me names in German ?

Tom, not sure what you mean. The premise for the plenums is to equalize the pressure/flow into the itb's. The plenums should help the itb's, not hinder them.

I was thinking more along the lines of intake reversion a N/A engine with a high-overlap cam. Probably not an issue with a turbo car.

Tom

[Steve@Rennsport]

Originally posted by emcon5
That certainly looks very cool, but doesn't the plumbing leading to a single plenum cancel out the benefit of individual throttle bodies?

Tom

Hi Tom:

LOL,..Oh no, not at all. In principle, this is similar to the factory 3.8 RSR ITB, dual-resonance-chamber manifolding.

Mark's design appears to have a single chamber and in a different position.

I'm unsure if this is intended for N/A or forced-induction applications,....

[MotoSook]

If you are going to the trouble of making the intake, why the throttle bodies at all?

..nice machining.