EOI: Aftermarket Intake Manifolds

6A13TT TYPE S

3 AYC Bars
Lifetime Member
Location
New Zealand
First Name
Adam
Drive
1999 Legnum VR4 Type S
At the moment in gauging the feasibility of making casting molds to reproduce in sand cast aluminum, the intake manifold which I have designed for my single turbo Legnum project. As I have had a few people ask me to make one for them.
here are a few photos of my prototype fitted to my car
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although the first prototype (pictured) was designed to have the throttle body on the drivers side of the car only. for the cast version it will be a symmetrical bolt pattern so the upper plenum shell can be reversed to have the throttle body on the stock side.
also my manifold is to suit a Ford FG Falcon 70mm E-throttle (drive by wire) I have yet to check fitment in the car with a stock "large bore" auto throttle body but i don't see it being an issue

here are some pics of stock intake vs my intake bolted up in both orientations

stock intake ... we all know what this looks like, (its shit (n))
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My Intake, "twin turbo orientation"
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My Intake "single turbo aka flipped orientation" (y)

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my current prototype has trumpets inside the plenum chamber, although i only did it this way because it was the way I could at the time. after some flow bench testing i have revised the design to having a bellmouthed edge as part of the plenum chamber base plate. this not only significantly increases airflow, but simplifies production and increases plenum volume.

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now down to some numbers.

the foundry needs to make one "cast prototype" to get the risers and metal flow through the mould correct. and of course needs to manufacture the patterns for the sand moulds.
this is the majority of the cost, (ignoring the post casting machining, milling, drilling and threading all bolt holes etc.

to create the cast prototype and evenly split the mould tooling costs the cost is

for 5 manifolds $2100NZD per person
for 7 manifolds $1750NZD per person
for 10 manifolds $1500NZD per person

this is cost price, I am not making a cent off this, Infact making a loss on each one after machining the castings and supplying bolts etc, the final sale price would be around 2000nzd after the first batch, just willing to offer the first batch at a lower price to help break up the tooling costs.


Of course a brake booster and boost reference port will need to be drilled and tapped in somewhere. but that can be easily done, even on the underneath if you wish for it to be hidden. and you clearly have to make intercooler piping to suit. for twin turbo fitment probably means ditching the stock airbox and battery to boot to make some sort of airbox in place of the stock battery.
for single turbo fitment, moving the rad overflow bottle and maybe tweaking the PS bottle bracket to fit I/C piping. also the dipstick tube mounting bracket would need to be modified as (with the falcon throttle at least) the dipstick is in the way,
You can get away with ditching the coolant feed to the stock throttle body.

if there is enough interest for this payment would be upfront to cover the prototype and mould costs.
and there would realistically more than likely be a 2 or 3 month lead time from puling the trigger on it to having a product in the post to you due to the prototyping and mould making processes.

any questions feel free to ask. and if your intrested in one either post here or PM me and ill make a list. if I get enough people we can start talking about time frame :)
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Blackbird

Leaving Skid Marks
Premium Member
Location
NSW
First Name
Steve
Drive
2001 ADM Evo 6.5 Makinen Edition,
2001 Legnum VR-4 Type S Written off,
2000 Legnum VR-4 Type S Manual with 23,489km!!
Absolutely EPIC Work mate... WOW!
Thing looks like Beast mode hit the 6A13 engine with a big hammer!!! Awesome work!!
 

Pal109

1 AYC Bar
Location
Melbourne
First Name
Paul
Drive
2001 Legnum Type S
Looking incredible with the development on this one, seems versatile with orientation too! In terms of the lower piece, is this being revised at all? Or is it close to being the piece you originally manufactured on cut runners?
 

6A13TT TYPE S

3 AYC Bars
Lifetime Member
Location
New Zealand
First Name
Adam
Drive
1999 Legnum VR4 Type S
See the 4th and 5th to last pics on the first post. Lower piece has been revised after flow bench testing.
This all bolts to the factory "Y" manifold so you retain stock fuel rails.
 

veegeeta

Leaving Skid Marks
Lifetime Member
Location
qld
First Name
shane
Drive
fto with 6A13TT & bf xr6 turbo
Put me down for single set up plenum. .. but it cant come any higher than original or ill have clearance issues in fto. Would be ready towards end of year
 

6A13TT TYPE S

3 AYC Bars
Lifetime Member
Location
New Zealand
First Name
Adam
Drive
1999 Legnum VR4 Type S
Its roughly the same height as a stock one. But it is full height further forward. So if your hood slopes away much quicker than a 8G hood it *may not* fit under the FTO.

Attached are some quick pics. It sits 150mm high off the top of the lower "Y" manifold and its 160mm wide if that helps you decide if itll fit.

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Pal109

1 AYC Bar
Location
Melbourne
First Name
Paul
Drive
2001 Legnum Type S
See the 4th and 5th to last pics on the first post. Lower piece has been revised after flow bench testing.
This all bolts to the factory "Y" manifold so you retain stock fuel rails.

I get why you are bolting it to the factory y piece now... , thats awesome for flexibility and great news for people running factory fuel rails!
 

6A13TT TYPE S

3 AYC Bars
Lifetime Member
Location
New Zealand
First Name
Adam
Drive
1999 Legnum VR4 Type S
I am working on another manifold which replaces the lower "y" piece to not have all 6 ports in a line.
but thats nowhere near even being done the CAD stage as im trying to make it sort of a modular design so parts can be changed to suit different throttles, but due to the narrow 60° V of a V6 compared to the big wide space of a 90° V8 its presenting some rather difficult packaging issues, main one being getting fuel rails in without having stupid injector spray angle into the port.

Anyways this current design adds plenty of plenum volume, and keeping the stock "Y" runners means its a good compromise between long and short runner. I.e still longer than your usual aftermarket plenum on a RB20/25/26, 1/2JZ , 4G63, SR20 etc etc but a good length shorter than the ridiculousness of the stock banana bunch :LOL:
 

Legnooms

Leaving Skid Marks
Premium Member
Location
Victoria
First Name
Tim
Drive
1998 Legnum Type-S VR4
2004 Ford Territory 4 sp Dual fuel
2006 Ford Territory 6 sp Dual fuel
But most importantly, can I get to rear plugs easily now?
 

veegeeta

Leaving Skid Marks
Lifetime Member
Location
qld
First Name
shane
Drive
fto with 6A13TT & bf xr6 turbo
Its roughly the same height as a stock one. But it is full height further forward. So if your hood slopes away much quicker than a 8G hood it *may not* fit under the FTO.

Attached are some quick pics. It sits 150mm high off the top of the lower "Y" manifold and its 160mm wide if that helps you decide if itll fit.

Ill measure up i think it might be right cause of the hole in bonnet no framing in that area.
 

Pal109

1 AYC Bar
Location
Melbourne
First Name
Paul
Drive
2001 Legnum Type S
I am working on another manifold which replaces the lower "y" piece to not have all 6 ports in a line.
but thats nowhere near even being done the CAD stage as im trying to make it sort of a modular design so parts can be changed to suit different throttles, but due to the narrow 60° V of a V6 compared to the big wide space of a 90° V8 its presenting some rather difficult packaging issues, main one being getting fuel rails in without having stupid injector spray angle into the port.

Anyways this current design adds plenty of plenum volume, and keeping the stock "Y" runners means its a good compromise between long and short runner. I.e still longer than your usual aftermarket plenum on a RB20/25/26, 1/2JZ , 4G63, SR20 etc etc but a good length shorter than the ridiculousness of the stock banana bunch :LOL:

This is kind of the conundrum I have arrived at... I was chipping away at a design and have observed the difficulties of packaging, being flexible with other peoples setups, and keeping the thing simple and easy to install or remove. It seems you can only pick two!
 

6A13TT TYPE S

3 AYC Bars
Lifetime Member
Location
New Zealand
First Name
Adam
Drive
1999 Legnum VR4 Type S
Yeah looks like stock throttle is a no go for twin turbo orientation as the idle stepper motor will probably foul the strut tower so im currently working on a cable throttle with external idle control.

Or you Australians could put a decent ecu on and use the ethrottle.. haha
 
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