I finally got around to installing the intake manifold I made. Well, it's mostly installed...there's a few things that have to be redone (water bottle catch can FTW) but it's in and the car runs.

The whole point was to be able to run the intercooler pipe thru the fender instead of between the radiator and the engine. I couldn't figure out how to do a decent sized over-the-radiator pipe while keeping A/C. And I had to teach myself how to weld aluminum.

I didn't have the time to do the intercooler pipe so I removed the turbos. Thanks to Paul for lending me the RB 4-1 header. As payment I'll fix the cracks in it.

Now it's a lot louder and a lot slower. Boo. NA sucks. I honestly have no idea how anyone can stand a non-forced induction miata. Damn.

BTW the car needed a decent amount more fuel in the part throttle zones.

 

it looks stealth bomber-ish. Whats that confangled contraption at the tb?

 

Looks like a canooter valve to me. AKA IAC valve.
Cool stuff, n/a sucks though. What sort of FI is in your future?
Also, how well did you like welding that cast aluminum to the sheet?

 

It's the stock (94) throttle body, just mounted upside-down. Paul also gave me a '99 TB that doesn't have the progressive linkage which will give me more clearance around the headlight motor.

Welding to the intake manifold wasn't as bad as I thought it would be. Welding to the cast waterneck for the coolant reroute was a lot worse (kinda melted like acetone on styrofoam) but fortunately the intake didn't give me as much problems. I welded the inside of the runners and tacked the outside. Then smoothed out/polished the entry to each runner.

Next is removing the borrowed header and old Enthuza (again, thanks Paul) cause it sounds horrible and then rigging my 3" exhaust with the OEM header, redoing the coolant reroute in aluminum hard line above the intake runners, oil catch can on the PCV line, overflow tank, 1.8l throttle cable (shorter), and of course the COPs!

First on the FI list is getting and installing the larger intercooler and piping. Most likely going to reinstall the TT's, but I may either build a single turbo manifold for the GT2871 (to fit my old 3" single turbo DP) or go with a different TT setup with the 2871 and my 2554. Depends on how long I want to go without boost.

 

NA does suck, but great job on the intake manifold. Looks nice.

 

too bad you made that thing to fit the 94 head...

 

i still envy your fuel rail, so simple and effective...
as far as tha mani goes looks beautiful man, can you still reach your oil filter from up top? and will the throttle body being upside down have any affect on the coolant flow? very interesting set up, i like

 

Thanks. Looks bigger in the pics than it actually is. It's not square in cross-section, it's trapezodial.

Too bad your VICS isn't hooked up.

Thanks. Fuel rail is cool Umm it's probably easier to reach the oil fiter from in front of the intake (where the TB used to be) you can easily fit your hand behind the alternator to get to the lower intake manifold bolts, so i think the oil filter would be easier to reach now. But I have always gotten the oil filter from underneath. Also, I am not running any coolant to the throttle body.

 

I'm surprised you didn't go with a mount for a bigger tb- like a mustang/tbird 5.0 70mm... or have you arranged for that? That's exactly what I need to do. My buddy built a similar approach, though from steel and then used silicone tubes to connect it to the chopped OE mani.

http://s50.photobucket.com/albums/f3...t=100_4341.jpg
http://s50.photobucket.com/albums/f3...t=100_4432.jpg

 

I seriously considered that. I have room for a 65 or 70mm honda TB, but IMHO either are not needed on a turbo'ed car and not worth the $150 or so. But there's room there in case I get convinced otherwise

I can always hacksaw the TB flange off and put a mustang one on there too.

Damn your friend's manifold looks pretty cool. Good ideas there, I like the runner inlets!

EDIT: After further review of his pics, that guy has way too much time...what kind of truck is that?

 

i wonder if the new mani futzed with your power curve and dropped your NA power. I can't imagine you spent as much time on a flow bench as mazda

better get that whirlygig back on there.

 

i really like that idea, i may utilize something similar on my mani design, but then again on FI is it needed? deos it help?
for the TB, you can "upgrade" at any time, junk yards are the way to go...

 

Heh, you need to borrow my pup for a "Xander on Manifold" shot

 

I figured the big TB would be in line with your lust for lots more power... tho I know it's really not a big deal with even ~300hp.

He has as much time as any of us (young single guys anyway). He just spent it on his truck rather than sleeping... and there's a lot of truth to that. It's a ford courier (b2000 to us in the US).

here's his build thread

 

True. My bend after the TB probaby doesn't flow as well as the straight-thru OEM (although the OEM mani does have some interesting protrusions inside the plenum). But I think any HP loss would be more offset by the gain in lower intake temps. Before, after just normal driving I could touch the intercooler outlet pipe and it'd be cool; the same pipe right before the throttle body would be too hot to touch.

 

And that's an FE3 huh? If so very nice, I'm jealous. Looks like a nice engine.

 

yes- it's a "bolt in" for the driveline with the big mazda trans too in the truck.

 

Hi, I am SOOOOO stoked that you called me young! and also that i'm your buddy :-)

understatement of the year on the sleep deprivation comment, for the last month in nz i was getting less than 5hrs a night everyday. worth it though :-)

cheers for the comments.

i have no pics of the front in one piece, but this one is pretty much identical to how mine started :

http://i50.photobucket.com/albums/f3...ourier1989.jpg
http://i50.photobucket.com/albums/f3...rier1989-2.jpg

this is mine taken from a video clip a few seconds before locking it up :

http://i50.photobucket.com/albums/f323/fredio54/ute.jpg

i wish i had a tig to make stuff out of ally like yours :-( one day...

fred.

 

i take my hat of to anyone who can see the potential in something like this, really, props to you, im sure it will end up beautiful though, im just saying that i would be affraid of attacking that...

 

fred, i browsed that build. you're nuts! i love it!

keep working on those welding skills man, you're getting there. oh and also what turbo is that? holset something.