b head intake

i need to prove something to a few fellows somewhere so im fabricating a 4v B head intake.....

this is the thread in corral. http://forums.corral.net/forums/showthread.php?t=1086421




here are the first few pics. they look like any other maifold mod from years past. the difference is, it will fit into a stang, and have 2 unique manifolds for each port.




drilling the base out


all cut out.



cnc mill im using



im probably going to drill the holes to a standard size and tap an plug them.
also im going to epoxy trumpets in the remaining runners after i drill them to fit in. you'll see as i do it.

weld the plenum back together. weld a box for the upper/lower to mate plenums. and the lower is done.

im going to mill the flanges where the secondary tubes were. drill/tap them for the secondary manifold to bolt to.

later

different views of milling a flange for the upper high rpm spider intake.

flanges cut.

You got my attention, but I'm wondering how you'll stuff 8 more tubes into that.

i wont be putting tubes into it. the holes where the tubes were removed will be welded shut with plugs.

a new 'spider' intake will sit on top of this one with its own plenum and injector bungs.

it will look very much like a taurus SHO intake.





of course this means when im done the turbo is getting pulled off and the motor will be rebuilt with stock internals. the compression now is only 8.5:1.

and for all motor 4v's spun 7200rpms, stock 93-98 4v internals are bullet proof. the rods are better than any other year beside 03-04. they have withstood 533rwhp.

i will have to get the crank rebalanced but you know rotating polar moment will be lower with counterweights ground down.

i will sell the whole turbo setup when i pull it. im keeping the pistons/rods.

it will include everything to simply bolt-onto a tubular k-member car. its able to feed the motor 16psi which is the highest ive run the boost so far. it will feed any other non ported 4v even easier. ill rebuild the turbo before i sell it.
it will include everything y-pipe, downpipe, intercooler, maf, inlet hoses, BOV, different springs for the wastegate, boost controller, boost gauge. i'll include the bullet muffler i never used. everything. you dont need a muffler on a turbo car.

billfisher wrote:i wont be putting tubes into it. the holes where the tubes were removed will be welded shut with plugs.

a new 'spider' intake will sit on top of this one with its own plenum and injector bungs.

it will look very much like a taurus SHO intake.

Oh, that is so slick. :*frank*: I can't wait to see it.

Would freeze plugs welded in work well enough? Assuming they're the same material, of course.

im machiing plugs from bar stock aluminum with bevels kinda like manhole covers. it will be tig welded from inside the plenum. th epsider intake will bolt onto the flanges i machined.

im still in the decision phase for rpm band i want. if i cam it and spin it 7200-7500 it will easily make 380rwhp. thats kind of the direction im going.

ah, that bar stock aluminum will be even better and look that much cleaner.

Waiting to see the final project as well..

Is this something you're going to use on the dragstrip? :*burnout*:

yeah its going to be used at the strip. i feel a lot better driving all motor at the track. not as hard on parts.

this new setup is for daily driving. more conventional. wanna tap the potential of ported 4v. ive talked to sullivan and have the specifics i need for runner design and plenum volume. their b head intake is still-born and they were nice enough the save me R&D time. my approach is different than theirs. variable plenum volumes.


you see the primary intake runners are going to have very little ram charging. they will operate mostly on vacuum demand. very little 4th order ram tuning. i do need the 140 or so cfm the primary offers, so im not restricting it. just setting plenum volume to maximize low end response.


im not finalized on exactly how little ram tuning im building into the primary plenum.

with the intake ill be switching to 4.30's and a 3500-4000 rpm converter.

what kinda price range are you thinking for the turbo and stuff?

ill sit down and figure it out a little later. i gotte get each piece off and inventory. im not gonna ask for too much though.

i may upgrade the turbo before i sell it.

you see im struggling with the primary plenum entries. i know what they NEED. but im trying to devise a quicker method of fabricating.

the main issue my eyes see is boundary layer issues from drawing a fluid directly from the roof of the intake. i am considering sand rolling the entries and milling the plenum roof around each runner entry to create a relief. but i know to be effective it needs height. my compromise would be to mill after 45 degrees of trumpet.

here is an illustration of the machine work concept. can't take 3 years to make this thing. some compromises need to be made.



the red area represents removes material.

pics are out of focus a bit. cell phone pics. im gonna go ahead and tig the plenum back together tonight.

plenum cover tig welded back on

btw i know the plugs look horrible. they are just for this intake. i WILL weld them up in later versions. no need with this being a prototype.


the lower intake will be done this week. time to order bungs and tubes.

impressive Bill, you are quite the fabricator!

How did you determine the correct volume for the sub plenum?

factory plenum volume is slightly less than 1/2 engine displacement.

on 4v plenum volume is not as critical as other motors. total volume for mine will be less than 300 cubes.

i talked to sullivan performance and they told me some of their findings on their stillborn b head intake.

milling the flange is all that is left for the lower intake to be finished.

Very cool!
You seem to know alot about 4V? You Wanna make mine a bas ass N/A 4V :*burnout*: