MONZTER

Yep that is where I was thinking. Tim had some good ideas that might help.

Hi Tim, Thanks for the comments, good Idea of making a couple extra ports in the vacuum log. I currently have provided for in rail #1 the Air Idle Control, and the EGR. In rail #2 I have provided for the MAP, Boost gauge, Fuel pressure regulator, and the Compressor bypass BOV. Can you think of anything I am missing?, or some suggestion for future needs? I really wanted to integrate the BOV into the back corner of the plenum tank (I have a Tial) but there is no room. I have pushed the engine back an inch and the plenum is close to the brake booster. My plan was to run it in the intercooler outlet tube in front of the core support, Do you have any suggestions or comments if this will be a good place to put it? Is there an advantage to putting on the plenum? Thanks Jeff

Good idea being able to get back inside it for testing and tuning. I looked into it but the part wall thickness would have to go way up which would add a lot of weight. Also, the plenum is really big, and I just have clearance around it for the booster, my header, wastgate and such. Welding it is simple and easy, and personally I like nice TIG welds in moderation. I guess I could always cut it back open if I had to. I also think I would have to have a wideband sensor in each exhaust runner to find variations, I am not ready for that yet. Jeff

So, I have pretty much finished the design for the turbo plenum. You can see in the pictures below the complete assembly. I have integrated the AIC system as well as the vacuum reservoirs into the backside of the plenum. Should make for some clean hose routing to the throttle bodies and all necessary systems MAP, FPR, gauges, BOV, AIC, EGR. In this new version I have smoothed out the entrance into the main plenum from the entry slot where it looked to be a problem. Turbobluestreak ran some new CFD plots of this rev. Check it out and let me know your comments. I have the stock on order and this thing will be in the machining center next week. Click on the pics for a bigger view

I think it looks great. Remember safety, not to sound like an old fart (I'm not), but it is the most important consideration in my opinion. It doesn’t matter how cool or light it is if it isn’t safe. With that in mind keep a close eye on the joints to make sure you do not have any issues with the wraps. If the frame starts feeling "soft" hang it up. With the BB installed backwards you may have to use some locktite on the BB threads and pedal threads to keep them from loosening. Again great job, you should try some tig welded steel next time. It looks like your miters are done well. Best Regards Jeff

I actually work as a Design Engineer for a bike company called Felt Bicycles. We do a few Fixed gear bike. http://feltracing.com/08/product.asp?catid=1504,1525&pid=8717 All of them come with a "peanutbutter" wrench with a bottle opener built into it. It mounts to the seat tube braze-ons with wingnuts. Good beer and bikes go together quite well.

Hey, Whats up with the LHD? You going to run fixed or freewheel with a front brake.

Custom frame builders actually sell this type of bike. http://www.calfeedesign.com/bamboo.htm Check out the prices. Good Job, and cut that steer tube before you hurt yourself...

From my understanding a thick cast manifold will loose heat faster than a tubular manifold. A thick manifold has much more heat soak ability than thin material, especially if the thin material is stainless. Stainless is a horrible conductor of heat, and great at handling the temps. Think of it this way, have you ever tried welding a thin tube? Low amps is all you need for good penetration right? Now try welding a thick hunk of metal, notice how much more amps you need to get the material to melt? This is because the thick heavy pc has more capacity to pull heat. If you design a good header with room for expansion, personally I think it is all good. I built my own and it was by no means cheap easy or going to give me back in performance what I put into it, but I did it because I wanted to and I like building. If you are on a budget with limited finances then I feel the money could be spent better somewhere else. For me I had no budget and just wanted to make the coolest header I could. Here are some pics of it tacked up Jeff

http://www.lumenition.com/new/main.php/throtb/

Tony I was just thinking about you comments on the old HKS manifolds. It sounds like the pressure drop in the large volume of the main plenum box isn't enough to balance out the floats. I wonder if you could tap into the system anywhere before the air goes into the large plenum and run this to the floats to get the boost like the sub plenum is providing. So a simple 4x4 box for the plenum with lines running to the float area to somewhere before the 4x4 box. Maybe before the intercooler?? Does this make any sense?? Just a guess

Not sure how the analysis was run, and if this was accounted for or not. This time I have to base the runner size on experience. Dave Rebello ported the head and was very specific about asking what engine size, cam, boost and HP goals. The end of the runners match to what he ported the head to. Actually not much bigger than stock. Interestingly the head flowed good numbers with the small ports @212cfm at 25" Dave said big ports doesn't necessarily mean good flow, but small ports help with velocity which will help with off boost performance. I guess well see Thanks for the comments, maybe TurboBlueStreak has some comments on how the test was run. Best Regards Jeff