JustinOlson

Overall picture: http://forum.vwsport.com/pics/data/500/injectorport4.JPG And the solidworks Zip file for anyone that wants to play around. (caution, the dimensions aren't correct at this point)

Here's a 2" thick flange with a bit of revision. It looks better to me. http://forum.vwsport.com/pics/data/500/injectorport2.JPG Justin

I was playing around with injector angle relative to the runner. I ended up making the flange 45mm thick and tried to squeeze in a 20 degree angle. Its just not thick enough as you can see how thin the material around the ports where the injector bosses are cut. Options are to either make the flange thicker, or port the head with larger injector cutouts. Full sized picture: http://forum.vwsport.com/pics/data/500/injectorport1.JPG Justin

Haltech E11V2 is a very good system. Regards, Justin

So what angle is good to mount the injector in relation to the inlet port? I'm thinking ~40 angle would work pretty good. I'm not sure tho. I'll be coming out the the campin I think I have to see what the plan is. Its going to be freakin hot this weekend, so I'm not sure. Justin

That would be cool. U presently have a N42 head here with both bolt patterns. So do the people with carb bolt patterns want injector seats integrated into the flange itself, or welded into the runners? I could produce just simple flat flanges for people to work with and do whatever they want with. Justin

The unit your refering to isn't a audi manifold. It is built by full-race and is for the EVO's. Regards, Justin

I'll redesign flanges with the carb bolt pattern today and get it to my machinist this week. I'll have a update later on this week. For flanges with the carb pattern, I am thinking I will move the injector ports into the runners a little ways away from the intake ports to help with atomizing the fuel. Which heads don't have the notches for the efi injectors? Regards, Justin

This gives me an idea that I would like to run my exhaust right down behind the front wheels and maybe do some sidepipes. It would be an easy way to fit dual 3" exhaust for a twin turbo v8

I'll be making a version that uses the older carb bolt pattern. That was the plan, but I just started with this head flanges as its more work. I would really like to see a full size version of this picture with all of the dimensions. It would be really handy for me to nail down some of the measurements as I dont have a set of calipers right now(mine were misplaced when moving last).

Links broken for me. Justin

update?

Call me crazy but, my girlfriend and I hooked up off myspace.

Heres a rough rendering of the flanges I think you'd need. I think your best bet would be to have flanges machined and then weld off the shelf stacks to them. This would be the most affordable solution I can think of. I went on to play around with integrating the stack into the flange piece. The downside to this is more machine work and higher material cost because those end up being fairly sizeable chunks of aluminum your machining. Also, the weight of doing it this way would be greater then welding a thin stack to the flanges as I've shown above. Heres a machinist nightmare... Muliple radius curve...

Thanks for the advice from those that have been there and done that. I guess I should just start out with some cheap "street" shocks and go as far as I can with them. Now, another topic, lightening up the strut tubes. Have people gone to lighter thinner walled material for the strut tubes? How about going to a strut tube that is thread the whole length to eliminate the need for sleeves. Has anyone machined lighter hubs and such. When I was at Rusch motorsports I picked up a sectioned strut tube and that thing was heavy as hell without the brakes caliper or rotor attached. I think on a "no rules" car you could take a lot of weight of the suspension pieces. Regards, Justin

Thanks for the advice from those that have been there and done that. I guess I should just start out with some cheap "street" shocks and go as far as I can with them. Now, another topic, lightening up the strut tubes. Have people gone to lighter thinner walled material for the strut tubes? How about going to a strut tube that is thread the whole length to eliminate the need for sleeves. Has anyone machined lighter hubs and such. When I was at Rusch motorsports I picked up a sectioned strut tube and that thing was heavy as hell without the brakes caliper or rotor attached. I think on a "no rules" car you could take a lot of weight of the suspension pieces. Regards, Justin

I like EZ wiring. Quality is just as good as painless IMO. $115 for a 12 circuit. http://www.ezwiring.com/minitwelve.htm'>http://www.ezwiring.com/minitwelve.htm http://www.ezwiring.com/

Update... Full Size: http://forum.vwsport.com/pics/data/500/headflange2.jpg

The only real street driving my car sees is driving to the track and to the grocery store once a week. I'm looking at either doing Koni 8611 double adjustables, AZC big shaft suspension or bilsteins.

The only real street driving my car sees is driving to the track and to the grocery store once a week. I'm looking at either doing Koni 8611 double adjustables, AZC big shaft suspension or bilsteins.

The plenum on the audi maniofold is just for the prototype. Its just to test fitment and throttle body placement. Once throttle body placement is verified I will be going to a nice tapered plenum like this:

I'm not sure that I can match $599 for a complete manifold with fuel rail and everything. I'll probably just be selling the head flanges for people to fab up whatever they want. The head flanges will come in at around $200 with fuel rail and mounting brackets. Regards, Justin

I'm just starting on the rough design right now. I have to finish up the cad model of this week and then I will send it off to my machinist to do a run of them with fuel rails. Heres my current audi project that is just rapping up to give you an idea of what the finished product looks like: Regards, Justin