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    Thread: supercharged 2.5l

    1. Banner Advertiser nothing-leaves-stock's Avatar
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      10-28-2011 10:45 AM #301
      you don't NEED a big plentum.
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    2. Member kevin splits's Avatar
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      10-28-2011 10:59 AM #302
      You still need one
      "The Vile Bunch" ll v2lab ll eemilitiatv ll Stay Orange.
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    3. Member mldouthi's Avatar
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      10-28-2011 11:16 AM #303
      I will model more at lunch.


      I will have to check the dims on the injectors also.



      How big of a pain is it to take the intake manifold off? Is it something that could be taken off to check fitment and say put it back on the next day? Gaskets?

    4. Member kevin splits's Avatar
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      10-28-2011 11:18 AM #304
      Quote Originally Posted by mldouthi View Post
      I will model more at lunch.


      I will have to check the dims on the injectors also.



      How big of a pain is it to take the intake manifold off? Is it something that could be taken off to check fitment and say put it back on the next day? Gaskets?
      I had it off last week. The underside bolts are the only ones that give a fight
      "The Vile Bunch" ll v2lab ll eemilitiatv ll Stay Orange.
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    5. Member mldouthi's Avatar
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      10-28-2011 11:22 AM #305
      Quote Originally Posted by kevin FaKiN spLits View Post
      I had it off last week. The underside bolts are the only ones that give a fight

      Thanks, Maybe I can bolt up the C2 flange this weekend and get a better idea where things will fit.

    6. Member mldouthi's Avatar
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      10-28-2011 03:26 PM #306
      Here is the whole system. The Grey boarder is 11.8 inches from the head (left to right) and the Bottom is 2.5 inches below the flange, and extends up 12 inches.

      The plenum is made of 4" tube sections and flat sheet. All .125 inch thick.


      Passanger side view


      Front View


      Passanger side section view



      With this setup, there will be a flange welded to the C2 flange and the plenum will have flanges on both sides. One to match up with the charger and the other to match up with the runner flange. The plenum will be bolted to the runner flange with 2 bolts on the outside ends and the rest will be bolted from the inside, between the runner holes. This can be done through the large hole in the charger flange. This design also utilizes a Bell awic core (6"x4.5"x1.25")

      I just realized I missed one flange on the s/c. Therefore there will be a .25 inch flange between the s/c and plenum that is not shown.



      Now let me know what you think of this design. Since its more finished now.

    7. Member kevin splits's Avatar
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      10-28-2011 03:38 PM #307
      That actually looks pretty good, tell you what make two of those flanges if you can
      "The Vile Bunch" ll v2lab ll eemilitiatv ll Stay Orange.
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    8. Member mldouthi's Avatar
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      10-28-2011 03:55 PM #308
      Quote Originally Posted by kevin FaKiN spLits View Post
      That actually looks pretty good, tell you what make two of those flanges if you can
      Will do, the material should be here in a couple days for the runner flange. I will make this out of something else, plastic or even foam to make sure it will fit before I go machining the actual flanges.

    9. Member Cherb32's Avatar
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      10-30-2011 05:40 PM #309
      Definitely want a SC rabbit...already setting aside money for a setup when you guys make one.

    10. Member mldouthi's Avatar
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      11-01-2011 03:12 PM #310
      I have been working on a bit of a variation to the design above. The new design will be a little easier for machining and will give 220 cubic inches of plenum space. I will also have some build drawings as well.

    11. Member TheZooKeeper's Avatar
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      11-01-2011 03:19 PM #311
      Quote Originally Posted by mldouthi View Post
      I will model more at lunch.


      I will have to check the dims on the injectors also.



      How big of a pain is it to take the intake manifold off? Is it something that could be taken off to check fitment and say put it back on the next day? Gaskets?
      You should be able to get the manifold off in under an hour, if you've never done it before. IIRC, they're o-ring'd at each cylinder port, so no gasket.

    12. Member mldouthi's Avatar
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      11-02-2011 03:16 PM #312
      Here is the new design, only change is to the plenum and the s/c mounting flange.





      This flange will allow for the bypass connection and the inlet and outlet of the awic. I have been busy at work and therefore I dont have many views and dont have all the drawings done.

    13. Member kevin splits's Avatar
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      11-02-2011 03:26 PM #313
      That looks great, exactly what Ive been picturing all along. but the port is to run a piece of silicone hose from the dv to that hole as a type of recirculation setup?
      "The Vile Bunch" ll v2lab ll eemilitiatv ll Stay Orange.
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    14. Member mldouthi's Avatar
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      11-02-2011 03:33 PM #314
      Quote Originally Posted by kevin FaKiN spLits View Post
      That looks great, exactly what Ive been picturing all along. but the port is to run a piece of silicone hose from the dv to that hole as a type of recirculation setup?
      That port will meet right up with the bypass hole on the cobalt m62, and use a rubber gasket in the channel. Therefore there will be no need for a silicone hose. Just 4 bolts and the charger is all connected to that plate.

      The other 2 holes for the awic can either be threaded for NTP fittings or have protruding pipes to run rubber lines and clamps.

    15. Member mldouthi's Avatar
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      11-02-2011 07:30 PM #315
      I just ordered a 2.6 LSJ modular pulley from zzp. Should put me at around 8-9 psi.


      I was also mis-shipped some material, so Im still waiting on my 1" thick plate to show up. But I got some free .5" out of it


      And I am getting enough material to make more than one of the manifolds for the people interested.

    16. Member Stg3G60's Avatar
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      11-03-2011 07:17 AM #316
      Quote Originally Posted by mldouthi View Post

      Hey man, from one fellow draftsman to another, really nice looking work! Cant wait to see when you have the setup fully machined. Awesome work

    17. Banner Advertiser nothing-leaves-stock's Avatar
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      11-03-2011 08:08 AM #317
      nice manifold.
      you have the pulleys lined up with the manifold spacing? or just make a killer looking manifold and hope the pulleys line up?
      www.nothingleavesstock.com
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    18. Member mldouthi's Avatar
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      11-03-2011 08:44 AM #318
      Quote Originally Posted by nothing-leaves-stock View Post
      nice manifold.
      you have the pulleys lined up with the manifold spacing? or just make a killer looking manifold and hope the pulleys line up?
      Of course I am not going to just hope it works. I will be able to make everything up to the s/c flange and the flange it bolts to on the plenum. That is why I ordered the pulley to check alignment.

      I will make everything except for the 2 flanges mentioned above and those I will cut to the right exterior dims and but no holes in the middle. Then mock everything up on the engine and hole the s/c in place on top of the intake and mark where it lines up. Then I can adjust the set of holes in the flanges accordingly.


      Or I could try to measure the offset.



      Ill probably do both just to make sure everything lines up.

    19. Member dhenry's Avatar
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      11-03-2011 08:55 PM #319

    20. 11-03-2011 09:44 PM #320
      did you ever get that c2 flange?

    21. Member mldouthi's Avatar
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      11-03-2011 10:11 PM #321
      Quote Originally Posted by tchilds View Post
      did you ever get that c2 flange?
      Yessir,

      I posted a crappy cell phone picture of it. Thats how I was able to model it.

    22. 11-04-2011 12:34 AM #322
      so that curved side on your intake manifold is going to be a pita, does it compensate for the longer bottom or something?

    23. Member mldouthi's Avatar
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      11-04-2011 06:59 AM #323
      Quote Originally Posted by tchilds View Post
      so that curved side on your intake manifold is going to be a pita, does it compensate for the longer bottom or something?
      It gives more room on the outside of the manifold for the fuel rail and plugs along with a smoother transition for the air. A curve on the other side doesnt help that much.

      It shouldnt be that bad actually. I am going to waterjet cut the 2 end pieces then the bottom piece is a rectangle and then all I have to do is hold a 4" .125 wall tube up to that profile and mark and cut.

    24. Member
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      11-04-2011 08:30 AM #324
      very nice models! I look forward to the end results!
      C2 tune, Peloquin LSD, .717 TDI 5TH gear swap, AWE exhaust, BSH CAI, H&R street sport coilover + 25mm RSB, neuspeed short shifter, 17x8 BBS RGR.

    25. 11-04-2011 05:54 PM #325
      so are the sides i was asking about equal length or i'm confused.

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