So I'm going to be building a new intake manifold and have a few questions that I'm sure some of you on here have already solved.
2.0L motor with 85mm 10.5 CP pistons, pauter rods, arp bits throughout.
99+ head with 270 deg cams, and other tasty bits. Headwork done by (now defunkt) replika machinen.
As a purchase of the motor I got an incomplete intake manifold. Starting from the intake tract:
Flange (looking at the backside) for a mustang throttle body, will support a 65mm throttle with no problem. I have qty 3 of this. I'll be running a 59mm throttle to start, because I grabbed it from a friend for free.
half round plenum intake, from ross machine, I need to buy this, looking at a 14" length, possibly 15" as a start point. If I cut off the flat section of the D, it will fit into my IM outlet flange (2 pics down) with little to no trimming. I will need to find a way to weld into the mustang flange. I'm not opposed to running 4" round tube for the plenum, but it would require more work to mate to the lower section.
end cap, I'm going to lay this on an angle to prevent a perpendicular end to my manifold
The output flange of the IM to the runners. I have qty 3 of these. The top flange shows output side, bottom shows input side, only one user per manifold. It is designed to slip fit a 2" OD aluminum tube into the output, and is setup to bolt on VW velocity stacks internally.
The sexy and I know it. Sadly quantity 1 on this part. Also setup to slip fit the aforementioned intake runner. This was done to allow for the prior owner to dyno runner lengths in short order. The flange is setup to take o-rings to bolt to the head, have plenty of those in stock.
Now that I've shown the start point. Here is the list of "issues" I know I'm going to be tackling:
- Throttle Cable routing
- Fuel Rail Mounting
- Vac lines/fitting
- Runner length
- Supporting the IM with everything configured as a slip fit
For the throttle cable, I think I can figure that out pretty easily by using the bracket I took off my 1.6 motor before I sold it.
For the fuel rail, I'm kind of stumped on this one and open to suggestions, build standoffs on the head flange to replicate what was done on the OE piece?
For Vac lines I'm tempted to drill and tap one line and then run that feed to a vacuum distro block for ease of later upgrades. If I build future IM's with my spare parts, I won't have to do extra drilling/tapping on the IM. However, it does complicate the engine bay.
PCV I'm not sure I'm running, most others I've seen have this plugged IIRC.
Runner length, I'm going to have to futz with this and maybe pick up some u-bends to cut to replicate the longer runner length. Then again I may do that with rev-2 and just get the first IM up and running with straight runners.
Supporting the IM. Obviously the block has a provision for a bracket, but I don't have one on hand, so would need to source or build custom piece.
I could buy a 99+ IM and bolt it on, but the intake ports won't line up well, lots of other work, and I'm thinking that with some effort this stuff could be solved quick, I'm hoping that someone on here that has done some of this can point out the gotchas, what to look for, or possibly even help a fellow MT guy in return for homebrew beer, homeroasted coffee, cash, whatever.
tl;dr: seriously, go read, pretty pictures and what not.