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Thread: 6A13TT Intake plenum, aftermarket?

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    6A13TT Intake plenum, aftermarket?

    SO I've been looking around for the last 4 or 5 months and failed to find much after market stuff for our 8G vr4's (I'm sure a frustration almost everyone here has).
    Specifically, a different air intake plenum, to make servicing spark plugs a 2 minute job instead of an hour job, replace lifters easily etc, more accessibility.

    I've been looking into making my own, read up about the affect of the length of the runs, the basic shape and volume of the plenum itself to avoid that pressure wave phenomenon, and I've come up with a design like this.
    Untitled.jpgUntitled2.jpgUntitled3.jpg

    This is only a rough as i took a tape measure to an installed engine, but it should be feasible and able to clear everything.
    If I was to make this (I work for a manufacturing company) or something similar once i have all the dimensions, Would anyone else be keen?

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    adaxo's Avatar

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    I think @Davezj planning to have a go with making plenum, all depends on cost of final product me think, lots of us would love to have this.
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    6A13TT Intake plenum, aftermarket?

    Are you replacing the plenum chamber and the inlet manifold?
    It looks like you are trying to do this, if so it is much, much, more work than just replacing the plenum on it's own.
    I did quite a bit of research on the subject a good few months ago, and you have to really careful you get you non turbo and turbo info separated as the theory is completely different.

    I looked into doing a mock up in plastic to do a test fit and possible final solution deepening on strength and heat resistance.

    But space got the better of me and I lost interest as I now have other issues to sort out before I tackle anything new.

    One of the issues is space, you would really need to remove the original air box and MAF to make it fit, so a MAP sensor conversion would be needed really just for space.
    Last edited by Davezj; 11-11-2014 at 10:02 AM.

    Bye for Now!

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    CANDEE's Avatar

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    @Adam.Findlay is looking into this atm.

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    Quote Originally Posted by Davezj View Post
    One of the issues is space, you would really need to remove the original air box and MAF to make it fit, so a MAP sensor conversion would be needed really just for space.
    Spot on. This would be part of a bunch of mods needed, custom hard piping one of them.
    I'm doing flow simulation at the moment and it's looking promising at atmospheric pressure & at 14.7psi (1 bar)

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    Adam.Findlay's Avatar

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    Yep you will want to make the upper half of the plenum a seperate piece or how else will you get spanners/sockets down into the V of the engine to fasten it down properly.
    The easiest way would be to design a plenum chamber which bolts onto the standard lower runners. and just manually port the stock runners to match the heads (you could even put bellmouths/velocity stacks ontop of the stock runners to promote airflow).
    the reason for this is the standard lower runners have a channel to evenly distribute air to all cylinders from the powersteering idle up valve. that channel also distributes PCV gasses.

    @Davezj you definatly DO NOT need to remove the MAF for space constraints. the easier option would be to just reverse the intercooler piping so the pre intercooler charge is pushed from the turbos toward the passenger side of the car, through the intercooler and back up the drivers side and then just have the new plenum have the Throttle body on the cambelt side of the engine. this reduces intercooler piping length and stops the IC piping having to run all the way across a hot engine.

    Anyway as CANDEE said I am in the middle of making a plenum myself however I am modifying the lower runners, however I am only doing this because I have to for the runners to fit my MiVEC cylinder heads.

    I don't have any CAD files but I plan to make the upper half of the plenum look much the same as this LS1 example
    https://eb9239d2b3c1bda1d53d-6b4eb89...om/300-126.jpg

    Plenty of plenum chamber volume. large throttle body sitting in the vee of the cambelt.
    as for the lower half it will be the standard runners cut up and modified then welded onto a plate which the top half will bolt down to, on this plate will have mounts for the fuel rails, Velocity stacks and a sealant groove.
    similar to this
    http://users.vermontel.net/~dcma/V6Swap/V6ITB2.jpg
    another example of 2pc plenum
    http://www.mirrorfinishpolishing.com...NIFOLD-672.JPG


    here are some pics of the chopped up lower runners I have so far sitting in place (pardon the picture quality as they were actually quick snaps of my turbo manifold but you get the point)
    I have removed the PCV and PS idle up channel from it as I had to to split them apart to fit the mivec heads, this is not an issue for me as I will be running an aftermarket ECU and emissions is not an issue here.


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    Cheers, Adam This is just a prototype, when ive got the dynamics sorted and real measurements i'll focus on making it user friendly to install, until then (also because the software is very picky) i'll leave it as one solid lump lol. Having it connect in several peices will be the easy part so that comes last

    PS I'll have to change my model slightly anyway, the throttle body opening needs to be bent down somewhat, like that LS1 example so it throws more air to the back, as is the flow is decreasing 7% from the nearest to furthest cylinder.

    PPS noticed the old school verniers on the ground in that last photo I've got a set of mititoyo digitals and I dunno about you but best investment I've ever made
    Last edited by individual; 11-11-2014 at 01:17 PM.

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    Nice info Adam, I had not thought of reversing the flow.
    I can see why you have done it, you have a very big turbo in the way.
    An interesting way of doing it.
    You have sparked my thought process off in another direction, not necessarily reversing the flow but different.

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    As is, it's not doing to badly, but it's a bit wonky for the first 20 iterations, it smooths out after that.
    This is just checking flow, not pressure or volume yet
    Untitled4.jpg

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    Adam.Findlay's Avatar

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    Sweet just putting in my 2c on the issues I have run into.
    look forward to seeing a result. the stock intakes are fuc**ng rubbish some good horsepower to be had in a properly designed one.

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    Did some flow testing on a basic mock up of the factory manifold, they like boost more than NA lol, turbo's cars seem to be more forgiving in terms of intake design, as there air is all forced in anyway, its not relying purely on flow.
    I'm just trying to find some runners to buy and measure, but not much luck atm. Don't want to take apart my daily if i can help it lol

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    When I make a design, depending how complicated some of the curves are, I'll make a negative solid (internal space) in several peices, to fit together after, leave them .2mm oversize, get them 3d printed, smooth it out and then wrap them in of carbon fiber, minus the throttle body mount and block mounts which will be easy enough to CNC out of 6061 or similar ally.

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    Can't wait to see the outcome guys,hope soon...

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    Any movement on this?
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    what kind of throttle body you whant to use?
    how much MM?
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    no further work done yet, most of my time and money is been spent on getting my legnum back on the road after a drivetrain/engine faliure unfortunately lol

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    Adam.Findlay's Avatar

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    Any progress @individual ?

    I'm part way through making one myself but still using the stock lower half plenum as its too much work to merit making flanges with non-perpendicular bolt holes and injector bosses with fuel rail mounts to replace it

    my design uses a spacer to raise the level of the stock lower half up high enough to clear the fuel rails to get a decent width for good plenum volume. this spacer lofts the ports from the stock 1476mm^2 square port to a 43mm ID (1452mm^2) round port to which I attach short 45degree bends to canter lever the ports away from eachother enough so that I can fit short ramtubes/bellmouths on the ends.
    The plenum shell itself is a flat sheet of 3mm thick alloy pressed into shape in a hydraulic press.

    hood clearance is the main issue, I feel I will have to sacrifice some plenum volume to allow my hood to shut properly.

    photos speak 1000 words so here you go. also more detail on my OZVR4 build thread post #223
    http://www.ozvr4.com/threads/adams-9....13822/page-12

    1.PNG2.PNG3.PNG4.PNG5.PNG20151014_183331.jpg20151014_183336.jpg20151014_183346.jpg20151014_183441.jpg20151014_183612.jpg20151014_183625.jpgbase plate.PNGIntake spacer.PNG
    Attached Images Attached Images

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    This is the sort of thing i have been looking for. I almost feel like we should have some sort of donation system to help with development of things like this. Maybe i've gone wacky. But the aftermarket options are almost NILL!
    Please keep up the good work guys. Highly appreciated

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    Donations are more that welcome
    If the prototype turns out well i might make 1 or two more.
    Last edited by Adam.Findlay; 21-10-2015 at 11:27 AM.

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    Quote Originally Posted by Adam.Findlay View Post
    Donations are more that welcome ��
    If the prototype turns out well i might make 1 or two more.
    I'd be happy to send a donation to help this

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