How To Make A Complete Inlet Manifold And Plenum

[ISL33P]

How to make a complete inlet manifold and plenum from scratch. Pictures tell a thousand words. The end plenum is exactly the same, just the base is a little simple.

All hand made, no cnc machine just a milling machine and a lot of patience and measurements as you can see.

Piece of 10mm aluminium plate

A lot of time measuring and drawing and then approximately 4 hours on a milling machine. Not electronic aids, just by hand

Base and bellmouths cut and ready to go

All in place and tacked together

Sheet of 3mm aluminium

Sheet cut up and engraved

Might as well throw in a throttle body since I have a few "lying" around

And the end result. Polished and blasted ready to deliver.

Obviously there is a lot more to it, but you get the idea.

For example

designing of plenum to not only fit but do the job.....runner size, diameter, dimensions, length, plenum taper etc etc

matching round bellmouth to a square port

final matching of runners & base once complete welded

machining the base to ensure a perfectly flat finish

polishing

fitment of vacuum fittings

throttle cable bracket on the bottom of the plenum

make and mount fuel rail

most circumstances, mounting of injector bosses

Your looking at approximately 3-4 days works from design to end product you see above.

More than anything, this will give you an idea of why custom parts (that have been proven) cost so much....and to tell you the thruth my costs are nowhere near what I have seen charged out there. End hourly rate is approx $40 per hour usually less, compared to some workshops charging from $80-120+ per hour it isn't really that bad.

Any questions, please feel free to ask.

Thanks,

Ariel

[VB-]

you mad c*nt, cheers for that

[Dahtone Racing]

awesome work mate

[STR8E180]

dam that flange plate is so perfect i thought it was CNC cut

my cnc machinest charges me 20buxs per flange but if he doesnt already have it designed he has to charge me 200buxs just for drawing it up on his computer

it does save time and for 20buxs a flange it works out eazier

for a hand made flange thats realli good, i realli thought i was cnc machined

Edited March 15, 2008 by STR8E180

[zebra]

Awsome Work.

Whats An RB25 Plenum worth....Do they use the std throttle body or one of the billet ones you have?

Cheers

Andrew

[secretgarage]

he did say it was all done buy hand and no computer controlled.

Which makes it a lot harder and much more tedious to acomplish!

and two still pull that sort of a finish off, man THATS GOLD!!!!!!!

love your work!!!!!!!!

please P.M me if you do big orders!

Edited March 17, 2008 by secretgarage

[benny_blanco]

is it all flow tested?

[typevu]

Thats some nice work there! Any plans on group buy on these?

[ISL33P]

thank you all. when it comes to machining the plate, an obssesive personality does help.

STR8E180 - thanks for the comment, much appreciated. Please pm details of your cnc machinist...thank you

zebra - pm sent on its way

secretgarage - pm sent on its way

benny_blanco - yes they all are. I am actually in the process of building my own flowbench at the moment to help reduce r&d costs.

type vu - Yes, I can do group buys on every plenum I offer.

For the sake of not upsetting moderators - I have already done that too many times - please call me, pm, email or visit my website for any enquiries.

Thanks again for the good feedback.

Ariel

[Craved]

Ariel,

Very nice work, uncommon for people to show the details of their work off for something like this, gives us tinkering bunch something to aim for in our own work.

[ISL33P]

Honestly, it was something I had second thoughts about but considering I will not disclose any measurements/dimensions etc etc, I thought what the hell.

Ariel

[Craved]

Honestly, it was something I had second thoughts about but considering I will not disclose any measurements/dimensions etc etc, I thought what the hell.

Ariel

still lots of thinking involved to replicate your work, but most who have the means to make this could work that out from scratch anyway.

inspirational though.

[raddavey]

Great write up! May i ask where you get all the materials from (bell mouths etc)? Is there an online shop that specialises in this?

And what do you use to bend the alumimum?

[ISL33P]

all materials are from www.jntperformance.com.au

only thing is all mine bellmouths are custom made and can not be on sold.....I have to keep some secrets

[Craved]

haha - fair enough you need to keep some things to yourself.

i just wish your logo wasnt so complex i've gotta try and powdercoat around it next week sometime

[ISL33P]

hence the new one in the sig

who's plenum do you have ?

Edited March 21, 2008 by ISL33P

[Craved]

hence the new one in the sig

who's plenum do you have ?

PM sent just incase

[crack]

all materials are from www.jntperformance.com.au

only thing is all mine bellmouths are custom made and can not be on sold.....I have to keep some secrets

i know steve weston well. used to work with him in brisbane.

[ISL33P]

absolute top bloke and does some real nice work

[dori34]

looks good man! price me on a rb25 one

pm sent

Edited March 24, 2008 by whyte