custom intake manifold design
The stock BMW TB is 2.5” in diameter, with a good chunk of the area being taken up by the butterfly, leaving not a whole lot of room for air to flow through. Custom Fabricated and Billet Intake Manifolds for Street/Strip/Track. The most common grade of aluminum metal suppliers sell is 6061, usually in T6 temper.
This meant adding a MAP sensor to the intake.
I asked PPF and they said that they’ve had good luck carefully crushing one end in a vice. Take a look at nearly any high horsepower racing engine and one of the first things you’ll likely notice is the intake manifold. I knew this would result in major surface marring so I made a little jig by cutting sections from a 6” aluminum pipe, welding them to flat bars.
It’s a robust design with large runners and flows surprisingly well. Sorry, your blog cannot share posts by email. It is almost as strong as 5356 with none of the concerns and most of the desirable properties of 4043.
I digress.
Runner length, plenum size, and countless other factors are optimized to provide maximum performance in each unique application. On a semi-side note, this was my first project using 4943. The TB itself is small, so even modified the largest aftermarket option I had seen was about 2.7”.
It’s also made here in town (Toronto) and for a great price, so I stopped by the K-Tuned office to pick one up. I decided to keep the plenum shape I had planned on but basically just having the throttle body on one side. When Visner Engine Development was founded, custom intake manifolds were the focus of the company.
Then one day while discussing Pure Performance Factory cams with a friend and cruising their website, I came across their fabrication components section and they made a CNC head flange and trumpets.
Very nice project. When I started the turbo project, it meant adding more vacuum references. 18 degree Chevy Pontiac small block nitrous intake, aluminum sheet metal ... 706 Intake Manifold Custom made by Weinle. Yes they do, although he’s since made new housings for round LEDs so it’ll look more E30ish. I began sticking things together. I had seen some aftermarket aluminum options, with a wide price range. High horsepower cars from classes like X275, Pro Modified, Pro Stock and others, rely on manifolds that are not the typical out-of … Inspiring! The intake manifold was originally the plastic piece from an M50 (the straight-6 used in the 1992-95 E36). Post was not sent - check your email addresses!
The next question was the throttle body. Maybe they go the wrong way and fly things over Russia from LA? The head flange is perfection. Sportsman, professional racers, and leading engine builders rely on us to provide the proper sizing, length, and volume for their specific application, based on over 25 years of on-track products success. I have watched it expand on the dyno as we hit north of 30PSI and it never gave up any of its nipples. It was scary to consider, but at this point, I knew that this had to happen. Or so I felt. But others’ experience reassured me that this would likely not happen.
Intake manifolds 100% custom made for your exact application.
I picked 3/16” wall, which is almost 5mm thick.
Our manifolds are engineered and designed with the knowledge gained over years of racing and winning. 6.5", 8.0" and 9.5" runner configurations for optimal tuning. I liked the look of the DI manifold, which emulated the stock one but with a deeper manifold and tapered front.
But then it worked and I bent the plate to shape in the vice using a thick length of angle and a solid rod.
The intake on my BMW E30 track car, like everything else on it, gradually evolved with project ideas and my ability to implement them (usually keeping my ideas at least a step ahead of my abilities). At home in race cars, sport touring builds, show cars, hot rods, off-shore powerboats and off-road trucks, we supply some of the most powerful intakes you can buy for naturally aspirated or boosted performance. For Big Block Chevy w/ 12deg Pro-Filer Heads. And to give credit where credit is due, the now 25+-year-old BMW manifold never failed. We build custom intake manifolds and related components. That didn’t stop it from bothering me. Again, in practice, it really seemed to work fine, probably because the intake was quickly pressurized so the delay in filling the outer runners was negligible. The general geometry of the manifold is also not ideal for a high-performance application, as the plenum is small and the runners are very long, both things conducive to low-end torque but not so well suited for high RPM jam. By Don Creason March 25, 2013. This page from Scientific Design of Intake and Exhaust Systems, by Philip H Smith and John C Morrison, gives an idea of how drastically runner length affects the amount and timing of peak torque. New website coming soon. Do those LED rings function as your headlights?
For more information or pricing, please contact us.
Like all non-ITB BMW owners, I suffered from major TB envy so I wanted to go big. At Marcella Manifolds we design and fabricate custom intake manifolds for any and all performance applications. I cut the shape out of 6061 sheet. The Carbon pTR intake manifold is built for boost with adjustable velocity stacks, Nitrous bosses, and integrated …
Hours: Mon-Fri: 10am-6pm • Sat: 11am-4pm • Sun: Appt only, Intakes are flowed on a new JKM Dual Flow, U Weld Sheet Metal Kits Offered at $1,000. Over the past few years, I had taken up TIG welding and had become quite proficient, including with sticking aluminum. Now I had to figure out the plenum. Each manifold is fully customized to the customer’s specific needs. Now I had to figure out the runners. Clamped the flange template to a big chunk of aluminum and welded the PPF trumpets inside. The tubes I got from PPF were mandrel bends at the correct angle but they are just generic round tubes.
Industry standard designs have been produced by years of research and development. Unmatched craftsmanship combined with record setting performance. Next was the size of the throttle body.
I read about annealing where you heat the metal past a certain point and it loses the temper, making it much easier to shape.
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