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Old 05-09-2009, 12:47 AM   #1
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Default New Turbo Manifold Design

My log manifold that I made several years back has developed a small crack btw cyl's 2&3. It's just enough to irritate me, and I've always felt like I could make a more efficient manifold so I modeled one in Solidworks. I think I saw TurboTim post a picture of a manifold of the same design some time ago. I haven't got any material yet, but I took my last final today and should have time to start tinkering with it soon. Here are a few pics. The collector should be interesting..








-Michael
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Old 05-09-2009, 12:54 AM   #2
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Yeah, looks kinda like an Absurdflow. Go for it.
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Old 05-09-2009, 01:00 AM   #3
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Looks VERY SIMILAR to the absurdflow which is proven to be a great design. I'm curious to see final results. good luck man, the design is great.
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Old 05-09-2009, 01:02 AM   #4
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Well, I had seen a mani by Neukin and one by TurboTim that I based it off of. Mostly TurboTim's. Tim, hope you don't mind.

-Michael
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Old 05-09-2009, 01:24 AM   #5
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Yeah, you've pretty much duplicated Paul's setup, just adding an external wastegate.

Shore Motorsports: Fabrication & Installation

What he did on the merge is a lot easier to fabricate than what your model shows.

I'm laying out a similar design for a WRX turbo. Have PS and A/C in the car, so I may not be able to package a symmetrical design. Due to that, and because the turbine inlet is round, getting the merge details right without some kluginess is considerably more complex. The T25's oval flange and 1-1/2 in. weld els make it easy.
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Old 05-09-2009, 01:25 AM   #6
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Tim's design:

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Old 05-09-2009, 02:20 AM   #7
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Well, im not sure if Tim's incorporated a T2 or T3 flange, but mine will be using a T3 flange. That's one of the pics that got me started.
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Old 05-09-2009, 03:24 AM   #8
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Looks incredibly nice. I love using SolidWorks.

I'm curious about clearance for the wastegate to the frame though. Will there be enough room?
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Old 05-09-2009, 04:26 AM   #9
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Looks a nice design that. I hate using solidworks though, can't stand it, much prefer using Catia.
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Old 05-09-2009, 06:26 AM   #10
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looks good. build me one too.

thanks >.<
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Old 05-09-2009, 08:13 AM   #11
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Quote:
Originally Posted by TheBandit View Post

heart shaped box



I like the design. That EWG placement should give great boost control.
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Old 05-09-2009, 10:14 AM   #12
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Quote:
Originally Posted by Orion ZyGarian View Post
Looks incredibly nice. I love using SolidWorks.

I'm curious about clearance for the wastegate to the frame though. Will there be enough room?
its gonne be really close and make the dump pipe difficult, hes better off putting it on the inside.

I want to know one thing. How does Tim figure out the proper angles when doing this.
http://www.shoremotorsports.com/pics...Primaries2.JPG
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Old 05-09-2009, 11:21 AM   #13
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Orion/Saml - That's actually something I'm not sure about myself. I've been trying to get an idea from the picture of Tim's. I may have to put another 90* bend there to move it out of the way of the frame rail. I'm not sweating it too much.

Saitrix - I just finished the CATIA course at school a week ago. I can honestly say that thus far it doesn't seem nearly as easy to use for what I am usually doing. It definitely has more capability. but thus far Solidworks win for the average Joe.

Simon/Gospeed - Thanks! It took several days to figure out how to get the the collector to come out like this. That was the only time consuming part. Ya never know. If I find an easy way to make it, maybe one day I'll make a couple more to sell.

-Michael
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Old 05-09-2009, 04:23 PM   #14
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Quote:
Originally Posted by gospeed81 View Post


I like the design. That EWG placement should give great boost control.
+1...wish my EWG was at the collector like that....
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Old 05-09-2009, 05:16 PM   #15
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It's an awesome design, used frequently in the Honda community.
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Old 05-09-2009, 07:24 PM   #16
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With Solid Works, is it possible to take the collector segments apart and define them individually?

I am faced with this on every MX5 manifold and it is rather painful.
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Old 05-09-2009, 07:43 PM   #17
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The way Tim did it, the merges are all on planes (he might even use a band saw, like the instructions for a straight merge on the Weirtech site). You can lay it out with pencil and paper, ruler and compass.

This Solidworks model is pretty, but the merges are complex 3D shapes. I can't figure out how to make them other than by spending 1000 years with cut and fit or CNC.

I think I've figured out how to make my merges at least planar, and lay it out and fabricate it, but there's a chance the tubes won't actually intersect each other perfectly at the planes. I don't have a Solidworks seat at work. I've thought about trying to use Google's free CAD.
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Old 05-09-2009, 11:34 PM   #18
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Corky - Yes, using the weldment function you can use boolean functions to combine and then split them. It will then create a seperate part file for each piece.

Solar - Your right, the merging btw runners 1&2 and 3&4 do have some very 3D complex geometry, which would be very difficult to make with out CNC capabilities. I may still have access to a CNC at my tech school, but if I don't I think I can go back and just cut them with a plane and get it "close enough". Although, I would much prefer to do it the right way.

Here is a picture of half the collector. You can see the complex geometry he's talking about a little better.




-Michael

Last edited by TheBandit; 05-09-2009 at 11:54 PM.
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Old 05-10-2009, 12:54 AM   #19
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Instead of coming straight out parallel with the block meeting flange, I think you should angle the wastegate flange upwards more. It has a good meeting point and I think any losses would be negligible.

I was going to say something about the 2&3's meeting into the collector, but there's not much to say. Its not that big of a deal really, and your way looks just fine and clean.
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Old 05-10-2009, 01:18 AM   #20
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was hoping you were going to make one for me out of the kindness of your heart. =P

but yeah would definately be interested in it, if your going to make some to sell later.
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