BRAMMER

iTrader: (23)

That looks really cool

Sonic Boom

iTrader: (11)

Looks amazing, will this be a one off or are you going put them into production?
Rich

nixon_2wd

Thanks guys!

One off for now mate

AustenW

Wow what a great thread, subscribed

opposite lock

iTrader: (3)

Must be one of the best threads ever for PF awsome project and skills.

Cossiemainful

iTrader: (1)

How much is it, mate? Wicked work!

L1AM_RS

Awesome! Some serious skill and machinery there.

Look forward to seeing the finished product.

Will you be running back to back with a standard inlet?

fury556

That looks bloody awesome!

The quality of the 3D rendering is amazing too!

nuttynil

iTrader: (3)

Incredible work ...... Well done

nixon_2wd

I do too!
Hoping to do some back to back testing, however I currently have a welded/modified elbow 4x4 inlet, so no completely standard inlet to compare it with.

Also remember that ITBs won't show difference in engine response on a dyno, though im hoping it will show a huge gain in torque over a standard one

Thanks for the comments guys!

CossieRich

iTrader: (1)

That's truly awesome workmanship Hope the results are as good as the product looks.

nixon_2wd

A small update on the project. Just picked up some more parts from Jenvey; once again awesome service from them!

Did some machining today, finished the idle air feed on the runners, and I am currently hand finishing them as that + boring and tapping the idle adjustment screw is the only part left on them now before powdercoat.

Later today Im hoping to make sand molds of the plenum, just waiting for the guy down at the foundary as he's a bit busy.

Some pictures:













How the linkage should look when it's complete:



Will be working on this non-stop this week so Im pretty excited!

XRT_si

iTrader: (2)

Bloody impressive!

nixon_2wd

Got some more work done these last few days, so Im just going to post all the pics. Enjoy!







Checking the temp before pouring:



Finished castings:







Second one:







Both:







And had to try





Started machining today





And thats where Im at now, more updates to follow these next few days Will finish this part tomorrow, boring it up to correct runner diameter, facing off the other side, boring and tapping, and then over to machining the other part.

Tev

iTrader: (2)

This thread just gets better and better! Top work bud

crazycage

Outstanding craftsmanship !

jsa

very impressive, are you doing anything with the exhaust side ?

It's Czech Mate

Like

closeshave

Awesome project! very impressive

andy escos

iTrader: (1)

Awesome skills mate

nixon_2wd

Thanks guys, appreciate the comments

Did some more work

Almost finished machining the plenum. Need to machine the flange down to the lower plenum, but have to cast that part first and then verify dimensions before doing so. Also need to fnish the holes for the injector sockets, but didnt have time this turn around. Just need to bore and tap them and theyre ready.

Also got the cylinder head to manifold flange / adapter cut in 7075-T651 aluminum, which is aerospace grade material.

Here are some pictures of the current progress:





And finally!













I did try with 12 bolts on the plenum cover and it looks awesome. Will take some pictures of that tomorrow or sunday, as in my opinion it completes the look!

Im also going to get all stainless steel bolts for it

nixon_2wd

Im playing with the idea, however I really like the design of Mark Shead´s manifolds. Just need to investigate them further such as sizing and runner lengths, and then decide if I can use it or not.

CrOwSoN15

Absolutely outstanding work!

MK MOTORSPORT

iTrader: (1)

hi
i think you are doing a very good job ,are you doing it all your self design ,casting and machining ,i think you ought to market this inlet i think you will sell quite a few and its good to see someone do something new off there own back and at there own expense
very well done

mark

nixon_2wd

Thanks for the comments guys!

I get some help with some of the CNC work by a friend, except from that Im doing it all myself. Remember that I got all the linkage, axels, bearings and seals, velocity stacks etc from Jenvey, and without those parts this wouldnt have been possible. They normally dont sell these parts separate.

Mocked it up complete with throttle plates, axels, linkage etc. and it looks pretty nice if I may say so

scoooby slayer

iTrader: (4)

that is absolutely awesome, the man hours you have put in must be a hell of a lot ?

you are doing a grand job

gus

iTrader: (1)

looking at the last couple of pics i cant see a feed from intercooler

apologies if its there im looking on my phone and its quite small

stu21t

In picture 1 you can see a flat oval section just under the water feed nozzle.

I guess there will be 1 big or 4 smaller slots there and a feed to the front will be bolted on.


Very impressive work.
After seeing what goes into design/make a part like this you can understand the high retail price of such a part.

nixon_2wd

No problem, if you take a look at the renderings you can see that stu21t is correct. I need to make molds out of that part and then cast it, just have to figure out the best way of orienting the molds. Thats the only part left, hopefully I will get it finished in a month or so

I know people are porting their MIS inlets for higher flow. These "bridges" are just there for added strength as the inlet tries to tear itself apart while under pressure. My flange design has reinforced that area, hence no need for bridges, just as the Jenvey-design. I have done a lot of finite element analysis on it to verify.

Also remember that this is ITB, and the lower plenum acts as a pressure distributor. Using CFD I have adjusted the slope and taper for equal distribution.

I agree. The prices asked for these parts are totally reasonable

Thanks! Yes the amount of time spent is insane, however engineering, 3d-modeling, CNC, casting, machining and Cosworth are all my favorite things doing and hobbies, so its just a way for me to spend my time Dont want to do anything else really

ts.tm.jb.fingers

unreal, what a master piece, the finished item will be the bollox, take my hat of to you,i know how long it take to machine parts like that, and even more time on setting it all up, keep up the outstanding work, great thread

nixon_2wd

Thanks mate, yes the time spent on setting the machines up and fixing the parts to the table almost exceeds the actual machining time lol. But thats how you learn I guess

It is actually unreal looking at it lying in front of me almost finished now

jonfoc

It truly is a great piece of work. 1 question, why only 1? You could sell these all day long I reckon

nixon_2wd

Maybe I can get it in production in the future, but I will need to alter the linkage design, axels etc and poduce my own complete system, as I will not replicate Jenveys design and try to make money of it Thats their design, and its great.

muz

Now, this is cool!

gus

iTrader: (1)

I would love one of those plenums

I'm running jennet itb's so aslong as all bolts up then I would be up for one of those

nixon_2wd

Maybe in the future, gus Dont know the cylinder spacing on those escorts (which is what I assume its for), is it the same as YB?

Glenn_

iTrader: (1)

That looks mint matey.

Joe Grp4 Escort

All the best for the finished project, hard work is paying off so far

nixon_2wd

Tested the fitment today









And I am gonna try with a 10mm spacer in the dynapack to see if it makes any difference, so checked the clearance for the strutbrace I have recently bought. Didn't mount the strut brace in this pic tho



Will be casting the final part and do the last bit of machining the week after easter And then the whole engine gets torn down and rebuilt with new pistons, Arrow rods, ported head and EFR xxxx. Just have to decide what EFR to go for..

stu21t

Wow.

Good luck mate.
If the engines 1/2 as good as the inlet it's going to be great!