A day on the flow bench

[David Buschur]

I don't think you did anything to him but he sure did kick you off his myspace page. Mike at AWD didn't do anything either but Wilson called him yesterday and told him to get in his car and deliver the fuel rail they sent him back to them. He told them to send a call tag for it he wasn't driving it anywhere. He didn't do anything either. Jim's loyalty is to money only.

[vwjeff]

wow man I am just blowen away here... Damn

sorry for the edit my phone is sweet sometimes

[David Buschur]

OK, I made some pulls on the dyno. At the same 30 psi I tested at last week the car is up on HP and TQ in the low/mid range compared to last time and the same up top. I just wanted to get a baseline and compare it for weather differences.

Now a few things I want to be clear on. The dyno sheet you are about to see shows three runs. The first solid line is my car and how it performed typically on the V2, on a good day it was in the 675 whp range. This can be verified by looking back over my old posts etc., for anyone who wants to do that. Then a few weeks ago I was going the SD muffler testing and the car was an absolute freak and put down 694 whp which it had never done before. Everything about the run was better than ever before. That happened one day in all the time I have spent on the dyno with the car. Since I used those graphs last time I showed what we were doing I am including them. Personally, I feel they have to be dismissed as it was COLD as hell the day I did that testing and the car never performed like that before or after that day. It is the best ever so I put it on the sheet.

Then today's runs were right in line with last weeks so I feel today's results of the BR stock ported intake are right on the money.

The details and I am sticking to what I see typically to what I saw today.

The V2 makes more power at higher boost/higher horsepower than the standard port work does.

The V2 on a typical day compared to today is up by 11 whp and 7 ft lbs of torque but still has the losses in the low/mid range as it does at 30 psi.

If you put the freak day with the V2 into the mix the low/mid is exactly the same (which I know is impossible from running it so many times) as the stock ported and up top makes 18 whp and 18 ft lbs more.

I've given the information in full, do what you like with it. My opinion is the V2 is better at this HP/boost level (41 psi/700 whp) over 5800 rpm and by a maximum of 11 whp and 7 ft lbs at 8,000 rpm. Because it does have gains from 5800 rpm and up the car would be quicker/faster in the 1/4 mile with the V2 over the BR ported stock intake. Now keep in mind it is a completely different story at 30 psi and 600 whp at those levels the BR ported stocker wins out by a higher margin and across the entire RPM band.

Here is the dyno sheet:

[celica2evo]

damn it, so the V2 is actually better. Guess Im holding onto mine until you get something that works as good.

[David Buschur]

We have made great progress today. I am taking a break from the fabrication side of the project as Trent is doing the final welding on the runners/stacks/plenum and end plate. I will be putting the finished intake on the flow bench today just to see how it flows and move the throttle body inlet around to see what effect it has on the flow in the runners/plenum.

Then we have to build fuel rail mounts and put all the fittings in for boost/vaccum and a dipstick mount.

I'd like to think by tomorrow we will have the first intake on the car.

Also, after putting the intake flange up to the head the entry to the head and the 10 degree angle do not match up very well at all. It was decided to leave the runner straight into the head.

I guess this is going to come down to runner length, velocity stack, runner dimension and plenum size to see if we've gone in the right direction or not. After I test it the next change will be to the plenum size, I want to go much smaller. It is approximately 250 cu in now. About 5 times that of the stock plenum. Many others are in the 300+ cu in range.

Just took the first measurement of the runners, they are as long as I can get them, 7.5". That's from the plenum floor to the head. I'm happy with that as I wanted long runners.

[David Buschur]

Brian, the V2 is better over 5800 rpm by 11 whp and 7 ft lbs at 680 whp and 41 psi. Correct. Believe me, I am trying my best for something better

[blackout]

Brian, the V2 is better over 5800 rpm by 11 whp and 7 ft lbs at 680 whp and 41 psi. Correct. Believe me, I am trying my best for something better

hahaha Dave, I think more people than just you are hoping you get better numbers than the V2.

[David Buschur]

Alright the intake is finished and I just got back from the flow bench. I do not have pictures of the intake completely welded up with the throttle body on it, we got pushed for time but you will get an idea what we've been up to by these.







Also for the flow bench numbers. These tests were done with our 65 mm throttle body on the intake just like all the others.

#1, 324 CFM (-1%)
#2, 329 CFM
#3, 327 CFM (-.006%)
#4, 321 CFM (-2%)
Total CFM 1301
The runners are 7.5" long
The Plenum is about 250 cu. in.

So we ended up with the most balanced flow of all the intakes and by quite a margin. The total flow I am shocked to see as low as it is. The runner with just the velocity stack on it (runner was short, total length from head flange to top of velocity stack was about 4") flowed 382 CFM. So we lost about 57 cfm per runner by putting the plenum on it and the throttle body.

As I have seen the flow bench isn't directly relating to what we see on the dyno so I am not getting discouraged or my hopes up. Just staying open minded. Tomorrow we will put all the vacuum ports in and get it mounted up and put on the dyno.

[steelcityevo]

very nice , looking good Dave.

I am very anxious to see how it does on the dyno tomorrow. Good luck !!!!

[wicked E]

Just a thought but maybe sticking a stock TB un-ported on it and seeing what that gives you for CFM?

-E

[vwjeff]

Holy SHIT Batman That manifold is SICK YO

I have 1 thing though... Will this fit on an ACD car. I remember the DI being stupid tight trying to sqeeze it onto the head with that line in the way.

[David Buschur]

This intake would fit nothing but my car or another car like it Jeff. I think you are thinking of the A/C lines not the ACD.

When I measured for the runners I didn't compensate for the studs in the head and let me tell you, it was a bear to get on the engine!!

I'm looking forward to tomorrow and dyno'ing it.

[SPIN2GST]

Eventhough I'm viewing this from my blackberry.....

That manifold looks tits!!

[SloRice]

[paris hilton]That's hot[/paris hilton]

[blackout]

Sick looking manifold, hope it bests expectations!

Jeff you are thinking of the ABS crap on the passenger side firewall I believe.

[SS Laser]

Dave,

What diameter are the runners? Are they the same size as the stock manifold?

If you figured the runners into the total size of the stock intake how many cu.in would it be? Same for your new intake?

I had a little different picture in my head of the "air horns" you were going to do. I can draw you a picture when I see you.

I wonder how the d-shape, oval, square plenum effect flow etc? I guess I wonder the same for the shape of the runner and taper?

Anyway looking good Dave!

[mullen]

very nice mani!!!

[vwjeff]

Dave maybe it was the a/c line? But either way it was tight

No Jan not the ABS pump, the DI is made with the end of the plenum cut at an angle to clear.

[johnboy1065]

I wonder if bending the runners would have any effect? arent the stock runners bent? i'd say it's hard to bend those very well though

[David Buschur]

SS Laser, I don't know, I haven't measured any of the things you asked me about.

Johnboy, the next intake I am going to try will have bent runner actually.