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 Post subject: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 3:48 pm 
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Location: Wollongong-NSW
Ive been told quad throttle bodies + Tighe 952 cams + Aftermarket ECU = Approx 115HP or 86KW ATW

Im going to give it a go.

Current Engine is Stock cultus = 84HP or 63KW ATW

Design Objective:
- Retain the brake booster.
- 4AG Quads off a toyota silvertop engine.
- Ensure air flow tapers dont exceed 14 degrees. (From UOW SAE students)
- Ensure all runner joins have no restrictions.
- Bonnet can close without cutting holes in it.
- Cool air filter system.
- Easy to adjust quads.
- Use original accelerator cable.
- Engine Air breather into manifold.
- Vacumm for brake booster retained.
- Looks good.
- Will handle race conditions.
- Low maintenance.
- High quality.
- Offer parts so others can duplicate this setup. (it is hard to find parts for gtis)

1. Started with measuring on the car the space I had available to fit the manifold and quads in.

Using Solidworks I drew a 3 dimensional space frame of usable area. This would ensure the manifold didnt encroach on the brake booster / firewall / bonnet / fuel rail etc.

I then measured and drew all the individual components in 3D. Manifold plate, quads baseplate, quads, trumpets, runner tubes etc.

I then made a 3D assembly of all the parts connected together. I started moving them around changing angles, ensuring runners were tangential, and at all times staying within the usable space frame work.

After about 100hrs of drawing, playing with angles, runner lengths etc. I locked in a design.
Attachment:
Manifold.JPG
Manifold.JPG [ 28.64 KiB | Viewed 163 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:17 pm 
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Location: Launceston, Tasmania
That looks and sounds great! Can't wait to see how this progesses and turns out! =D>

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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:25 pm 
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Location: Wollongong-NSW
I then CNC machined the
- manifold plate
- quads baseplate
- Runners to oval transitions


Attachments:
20131030_170118.jpg
20131030_170118.jpg [ 660.01 KiB | Viewed 180 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:30 pm 
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Then made a jig plate from dimensions from the 3D solidworks model.

Bolted the manifold and quads plate to the jig.

Cut the mandrel bend runners to the angles determined from the 3D model.


Attachments:
20130920_173434.jpg
20130920_173434.jpg [ 196.9 KiB | Viewed 180 times ]
20130920_195536.jpg
20130920_195536.jpg [ 871.74 KiB | Viewed 164 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:34 pm 
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Finished tacking together and welding.


Attachments:
20130920_201344.jpg
20130920_201344.jpg [ 804.14 KiB | Viewed 175 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:37 pm 
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Location: Wollongong-NSW
Finished welding


Attachments:
20131030_160222.jpg
20131030_160222.jpg [ 642.99 KiB | Viewed 183 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:39 pm 
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Runners were ground for smoothness.


Attachments:
20131030_160240.jpg
20131030_160240.jpg [ 267.78 KiB | Viewed 180 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 4:42 pm 
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Trial fit on dummy engine.


Attachments:
20131003_112347.jpg
20131003_112347.jpg [ 333.69 KiB | Viewed 178 times ]
20131003_111948.jpg
20131003_111948.jpg [ 318.94 KiB | Viewed 167 times ]

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05
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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 5:16 pm 
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Joined: Sat Mar 08, 2008 1:07 pm
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Location: Western Australia
Hi,

Nice build! =D>

How will you get a MAF and TPS signal to your chipped ECU? I'm guessing that you are intending to upgrade to a stand-alone unit soon?

Cheers,

Drew

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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 5:34 pm 
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Location: Wollongong-NSW
Tps gets fitted on end of quad in last photo.

Planning on fitting a Motec m84.

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Retired the gti after 12000 track kms of fangin around.
Eastern creek 1.54.10, Wakefield 1.12.60 Bathurst 3.05


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 5:42 pm 
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Joined: Fri Oct 21, 2011 4:58 pm
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Location: vic
racer5 wrote:
Tps gets fitted on end of quad in last photo.

Planning on fitting a Motec m84.


Love your work man...


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Oct 30, 2013 5:45 pm 
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Location: Cessnock
Nice work mate, been looking forward to seeing the finished product!

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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Wed Nov 06, 2013 6:30 pm 
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Did you check the angle the air will have to turn from the manifold plate to the port entries to valves?

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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Fri Nov 08, 2013 9:18 am 
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Location: Camden
Those welds look amazing!

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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Fri Nov 08, 2013 6:11 pm 
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Posts: 41
Location: Sydney
Geez, all that work and money for only sub 100hp power? I would be very disappointed. A standard starlet GT has more power. Should just fit that.


Secondly, the noise the car would make will not be a sensible street driven car, plus you would have to rev it of its head just to make power. Your ears will go quicker than your enjoyment.


Hmmm, fitting a $2500+ Motec for only 100hp.


Whatever floats your boat.


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Fri Nov 08, 2013 6:24 pm 
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Posts: 812
Location: vic
G13BJimny wrote:
Geez, all that work and money for only sub 100hp power? I would be very disappointed. A standard starlet GT has more power. Should just fit that.


Secondly, the noise the car would make will not be a sensible street driven car, plus you would have to rev it of its head just to make power. Your ears will go quicker than your enjoyment.


Hmmm, fitting a $2500+ Motec for only 100hp.


Whatever floats your boat.


I've got a nice rope here for u
Ill send it to you for free..
Please hang your self buddy
You know f**k all


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Fri Nov 08, 2013 6:28 pm 
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Posts: 489
Location: sydney
:lol: use the rope your self cappa
[-o<


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Fri Nov 08, 2013 6:59 pm 
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Posts: 1200
Location: Kurrajong
^^ haha yes!!

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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Fri Nov 08, 2013 8:01 pm 
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Location: Chch - Quake Capital
Guys STFU, don't fill up this good thread with all that trash talk, take it else where.

Racer5 any chance you can weigh that manifold??? workmanship is outstanding even if I don't agree with all the bends and sucking air from the hottest part of the engine bay where it's trapped, I would be looking blanking off the entire front except for the radiator and using a small scoop in the bonnet to force air into that manifold.

Credit where credits due, nice workmanship =D>


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 Post subject: Re: Quad Throttle Bodies with clearance for Brake Booster
PostPosted: Sat Nov 09, 2013 5:49 am 
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Location: Camden
Did you do the welding?

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