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#Post#: 917--------------------------------------------------
Golf 16v Custom inlet plenum.
By: Smudge Date: September 10, 2013, 2:15 pm
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Hello all, I thought you may be interested to see my recent work
on my inlet manifold, it has now been fully tested on track and
with Jason on the rollers and has proved on my mild engine setup
to be quite effective after it replaced the home brew ITB setup.
#Post#: 918--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Smudge Date: September 10, 2013, 2:16 pm
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I set about buying some parts to use. The inlet track on the
manifold needs a curve so that the plenum fits under the bonnet,
the KR 42mm inlet is perfect for this job, it has the correct
bore runners and the curve is perfect. In the vice, I cut it
down with a hacksaw.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/0A2B72C0-3E6F-475E-BBA5-A7680CCAC40A-3245-000008FEC3CC513B.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/D6412087-94CC-4111-A669-53FD082F4ABC-3245-000008FED9FA2E03.jpg[/img]
For the flange that bolts onto the head I used the lower section
of the same manifold and cut it down, then milled it flat.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/C01E17BF-6F1D-4A15-87DA-47A1C48C9014-3245-000008FEF39BE4C3.jpg[/img]
I also reclaimed the flange of the other end and will be using
this too. Here are the basic components ready for fabrication.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/DAA66EC0-6716-4E60-8FBA-AD2C94F4B389-3245-000008FEEE83FB1D.jpg[/img]
#Post#: 930--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Smudge Date: September 15, 2013, 6:44 am
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To mate the runners to the head flange requires the ends of the
runners to be oval. I achieved this by squashing them in a vice.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/C768984B-B206-4B57-8AAB-4787D78B20B6-3245-000008FEF8C105EF.jpg[/img]
I chamfered of the edges so that I got better penetration when
welding and tacked into place.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/C628115B-6CD2-4F08-99FC-9961F372AAF1-3245-000008FEFDD794C3.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/4AC49A12-B3DD-4A67-B17E-64CD2070202D-3968-00000C7324248E4A.jpg[/img]
After tacking into place I test fitted onto the car.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/DF12AF32-26E9-485C-A804-973F67BC225D-3245-000008FF02B6520C.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/54364107-8C13-47AE-AE79-DBAA39CB1501-3245-000008FF100BFED4.jpg[/img]
#Post#: 934--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Robin_16v Date: September 16, 2013, 2:32 pm
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Nice work!
#Post#: 945--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: JMR Date: September 19, 2013, 4:19 pm
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Keep em coming Tom... ;)
#Post#: 947--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Smudge Date: September 21, 2013, 3:37 am
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After tacking in place you can see the step here that needs
blending out, it's only small and to the sides only. At the
point where the runners join they slightly squash in (to avoid
spark plugs in OEM application) so I also built this up with
weld.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/D98D18A7-6847-4370-98F8-687F69C045C8-3968-00000C72D064004A.jpg[/img]
To keep the wall thickness the same at the blend point I welded
on extra material.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/4AC49A12-B3DD-4A67-B17E-64CD2070202D-3968-00000C7324248E4A.jpg[/img]
And then ground it all back.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/8103D73F-B168-46A7-BFCE-556181E81507-3968-00000C72D745311E.jpg[/img]
#Post#: 950--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Tonyb Date: September 23, 2013, 12:20 pm
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Nice use of std parts Tom. Be interesting to see how it flows
when it's done. What are you bolting on to them? be nice to use
8 injectors with the bottom injector holes still in the head
end.
I looked at using an 8v OEM manifold once for injection but that
is a tricky beast, especially if you havn't got the kit to weld
aluminium.
#Post#: 951--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Smudge Date: September 24, 2013, 11:25 am
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Hi Tony
It's actually finished and has been on the car for a while now,
it would be great to measure the flow and I might have to post
it down to JMR over the winter months to find out. The aim when
building it was to keep the peak flow as close to my ITBs as
possible, but I'm sure having a plenum will be a factor.
#Post#: 952--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Smudge Date: September 24, 2013, 12:08 pm
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To finish off the inlet track I bought some spun ram pipes and
welded them to the flange, I had to keep the back plate in place
as I did this, it was tricky to say he least!
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/9F1C568E-AFE6-4A11-AE6C-B221D88AFE3A-3245-000008FEE87EA353.jpg[/img]
Once tacked into place it was again tested on the car for
fitment before welding fully.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/A17BD654-9ACB-43D3-8DBE-C5ADE6A884E1-3968-00000C7337137921.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/D9D9E062-001B-4DF1-B535-96D5B714B70C-3968-00000C733CF238F1.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/137566A5-ABF8-4EA5-9CA5-9058248BB55C-3968-00000C72F35F2AC4.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/9FCDDF9A-08AD-4EFE-925F-E7094505090E-3968-00000C730FC5F9AB.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/EECD9B69-2A12-46F3-A02F-E5005BCC8C09-3968-00000C730A0E4B9D.jpg[/img]
Where the ram pipes join the flange some blending is required.
There is plenty of meet on the flange to allow this.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/72EA5017-89CC-4AD5-AEAB-3A9143344A95-3968-00000B365D622C6D.jpg[/img]
#Post#: 953--------------------------------------------------
Re: Golf 16v Custom inlet plenum.
By: Smudge Date: September 24, 2013, 12:13 pm
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Confident the inlet would fit after testing I set about
fabricating the plenum chamber.
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/8ECC5685-7678-46E9-94CA-D086304718E7-3968-00000C7471B4AEA1.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/909D58C0-6B01-4362-BB22-DEF0817496A6-3968-00000C747959092C.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/9C2177B0-9661-424E-9CA3-FD1897F69511-3968-00000C7364D6641B.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/A1E63E28-ACC2-46D6-BE30-AEC90C43938D-3968-00000DCA98EC55E7.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/07309DA7-9A76-453B-99C0-C8740070ED07-3968-00000DCAA061119C.jpg[/img]
[IMG]
HTML http://i64.photobucket.com/albums/h199/the_smudger/D6832324-971E-4E9A-B833-4ED04E204F03-3968-00000DCAA54DF068.jpg[/img]
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