"Ray's AKA demonfire's XR4Ti build up"

[Ray]

Got a little more work done - waiting on a few bits for finalization, but here is where we stand.

Spent a while smoothing and polishing - too bad this will be hidden. For clearance concerns - remember, the stock manifold goes OVER the intake manifold. This is a full 1.5" lower than that.



stainless tape, i love it for mock ups.


another view



16ga to 1/8 weld...


another test fit.


and, the end of today's work. All seamed except for the top.


Plenum volume is just over 3 liters. Actually, a question - do you include the runner / inside the stack volume in this calc? If not, then it's just shy of 3 liters.
Either way, should be a market improvement over what i had. We'll see.

[DSPXR4ti]

Got a little more work done - waiting on a few bits for finalization, but here is where we stand.


and, the end of today's work. All seamed except for the top.


Plenum volume is just over 3 liters. Actually, a question - do you include the runner / inside the stack volume in this calc? If not, then it's just shy of 3 liters.
Either way, should be a market improvement over what i had. We'll see.

Can you set it up so you can screw down the top, so you can do inspection if you need to, cracks and other ?. I like that you put the TB on the one side to get the swirling effect.

Did you think of making it round to enhance the swirling effect.

Ben

[Ray]

I did think of it, and am considering adding angles inside, yes.

[Ray]

Ben, instead of a removable top...



welded


1/2" high impact polycarbonate


voila


getting the nuts on the bottom of those bolts was a pain.




more clearance than stock to the hood - only close to the brake fluid reservoir, but i'm not worried.


note: NOT DONE WITH THE LOWER MANIFOLD YET; this is just mock up / test fitting. I plan on spending some quality time with a file / air grinder to radius the lower.

[DSPXR4ti]

[quote="Ray"]Ben, instead of a removable top...
voila


This is going to be cool on a dyno under full boost, Your going to have to get us some Vid of that.

Very Cool.

Ben

[hEaT]

Anyway to get in there with a torch and tack those nuts on? May be able to pop the top off, put the bolts back on tight and make those captive nuts if you haven't already.

Knowing you those are nylocks? I'd feel better about knowing those cannot and will not ever come loose and fall into a runner because they're welded to the plenum. Weld em, add some 242 Loctite and not worry!

[nathankershaw]

That is awesome!

Good job, love the Perspex lid.

Well done.

[Esteban]

Why not just bolt the throttle body to your plenum? And why not move the inlet towards the center to get it aligned with the intercooler outlet? Clearance issues?
Sorry for all the questions, just curious.

[Ray]

Joe, i am using milspec nylocks for the nuts - i dont anticipate them coming loose, but i have a good visual if they start as i can literally see them. if it ever becomes an issue i'll revise it.

Esteban, i didn't even consider bolting the throttle body to the plenum, to be honest. I have it over to the side to aid in the swirling effect, as well as ease installation of the throttle cable. I am not worried about my existing intercooler tubing as i am changing to a larger intercooler in the off season as well so i'm going to be changing all of my intercooler tubing anyway.

[merkurdriver]

Coolest looking 2.3T intake I've ever seen

[hEaT]

Joe, i am using milspec nylocks for the nuts - i dont anticipate them coming loose, but i have a good visual if they start as i can literally see them. if it ever becomes an issue i'll revise it.

Gotcha. May be easier to R&R with captive nuts. Not sure how the access is.

[Ray]

Would be loads easier to R&R with captive nuts, putting those on took me too long, but now i know the "method" to at least ease it. Making captive might be a chore tho - hard to tack weld steel to aluminum and all that.

[Ray]

Existing FMIC setup, from the bolt on flange from turbo outlet, to the upper intake manifold will be for sale soon. PM me if interested before i put it up for sale. Will be turbo outlet, piping, t bolt clamps, couplers, intercooler, mounting brackets, return pipe with tig welded flange for IAT sensor, and upper intake manifold, basically a bolt on rotated intake setup - pricing to be announced soon.

[catapultkid]

How hard was it to weld to that stock casting? I've got to clock mine very soon and looking for advice.

-Paul

[Ray]

Stock casting is a "porous cast" so it's super imperative to get it clean clean clean. It absorbs oil and contaminants.
If you get it clean enough - it welds fairly well. When i was building the plenum intake manifold it welded VERY nicely to 6061 with 4075 rod (i think, need to double check). But i cleaned, sanded, cleaned, scotchbrited, acetoned, and wiped down prior to welding. Even then i got some tiny black fleks floating to the surface of my puddle. If you cut the material with a bandsaw, not a chop saw or angle grinder, you'll see the porousness.