CAE86 ITB Build

[GTSRolla34]

Thought I'd give some more info on this stuff since I've been posting random images. I'm stuffing a CA18DE into and AE86. I have two sets of 4AGE 20V ITBs laying around and figured why not design an ITB manifold to work with the CA. I got it all done, but realized that to have just one milled was going to be $$$ so I put it on the back burner as a dream project. Well, the machine shop at my workplace said they would machine it and despite offering to pay, they said they'd machine it for free. The lack of incoming work left them with a lot of free time and they said they're getting paid regardless, just to show up at work. So, I went from:








To:









The machine shop still has a couple hours of machining to do on it to clean up the edges and they said they're going to polish it up. They still have to match the taper on the ITB bores and drill out the injector bosses as well. The figure '8' piece on the head flange had to be redesigned due to restrictions caused by the type of CNC machine they have. They're going to make a 1/2"-3/4" thick spacer flange that will have those curves included.

Here is the vehicle as she sits right now:




















My full build thread can be found on a couple forums, but I update this one first:
http://www.86garage.com/forums/viewtopic.php?f=8&t=1459

[themadscientist]

Your 4AG looks strange.

[float_6969]

LOL! It looks better IMHO.

[nissan_guy240]

Your 4AG looks strange.

lmao

[GTSRolla34]

Well, I've been nervous about actually sizing it up against the head. I've only been able to test fitment by printing my workflow images from AutoCad/Inventor. Seems everything is going to be okay though:










It's not seated completely against the head in the images. I need to clearance the bolt holes a tad bit. Good thing is that all the cylinder ports and the coolant passage line up as I intended them to.

[sjbsuperman1425]

so the injectors are going to be mounted underneath the manifold?

[GTSRolla34]

Yeah, I wanted to keep the top clean looking. I could just as easily designed them on top, but I though this would look cleaner.

[sjbsuperman1425]

alright, it was just something I've never seen before so I thought I'd ask lol

[leadpaw]

Just out of curiosity is that a Ca18de out of a Fwd pulsar?

[GTSRolla34]

Yes it's a FWD CA, but it came from a Nissan Bluebird in Japan. Not sure if that makes a difference.

[GTSRolla34]

I had the bore milled close to the Silvertop ITB bore. It's actually a little indersized. I planned on using the BT ITBs from the get go, but the ST bore was easier to design. The BT bore will solve any alignment issues that are present.

[Razi]

Looks amazing!!!

[ganma_ca]

Dude that is so legit!!! Awesome build man! Want to produce a few for us lol? Not that I could afford it but man it's awesome to see someone create something EPIC for the CA right here on the forums.

Will look forward to a vid after you get it tuned and setup!

[ragenasian]

CA looks right at home in the AE86's. Maybe I will get my CAE86 done one of these days.

Looks good, keep up the great work, and keep up updated.

[s13drifter88]

if there is another one made you have a DEFINITE buyer right here!

[float_6969]

Make it for a 4 port and I'd be all over it!

[GTSRolla34]

I could easily alter the design for a 4-port manifold, IF I had a 4-port intake gasket. Then I could get the port sizes and spacing tweaked. I may be able to do so from a picture of a 4-port head, but I would be nervous about the accuracy of the images scale. I could also put the stock CA thermostat port on the drawing for those who would wish to retain the CA's RWD thermostat housing.

[s13drifter88]

I want 4 port

[GTSRolla34]

I scaled that from an image of a 4-port's intake ports, but I don't think it's accurate. The image had some skew to it and I think that's messing with the spacing.

[r34 gtr]

I dub this here build the "High 'Rolla." Also, if you do not keep it panda, I WILL find you. Nice job so far!

[GTSRolla34]

Panda? The car was black from the factory and then the previous owner primered it gray before he sent it to the scrap yard. It's in need of a clean paint job...white is probably going to be the color, but I don't see the panda scheme coming in.

[r34 gtr]

Ah, my apologies then. In the very first picture of the car, the fenders look white and the rocker panel looks black. However, panda ae86s look super awesome and you should strongly consider it.

[GTSRolla34]

No big deal. I thought about the panda scheme for a while, but the all white with black bumpers and white skirts just seems cleaner to me. If I go all white from the get go it will be no problem to lay some black over if I ever felt like it.

[ragenasian]

I could easily alter the design for a 4-port manifold, IF I had a 4-port intake gasket. Then I could get the port sizes and spacing tweaked. I may be able to do so from a picture of a 4-port head, but I would be nervous about the accuracy of the images scale. I could also put the stock CA thermostat port on the drawing for those who would wish to retain the CA's RWD thermostat housing.

If this is possible I will send you a gasket. I am in the land of 4 port so an intake gasket is not a problem at all.

[GTSRolla34]

Sweet. If you ever get around to it, shoot me an email: [email protected] and we'll work things out.

[nissan_guy240]

if there is another one made you have a DEFINITE buyer right here!

add me to that list

[CA19DET]

ohhh, how much for that intake manifold for the 8 port to use the BT/ST 4AGE ITB's??
me like for my datsun

[GTSRolla34]

For anyone who may have need for one in the future, I'm starting to modify my design to fit over the lower manifold. This way it can be used for both 8 and 4 port heads.

[float_6969]

Are you sure that's going to leave enough clearance for a plenum?

[GTSRolla34]

I'm not sure. I'm going to take some measurements once I have a basic design set out. I'm reworking the head side flange now. Plus, I'm working on an AE86 chassis so space may be different. If anyone has a measurement from the face of the lower manifold to the shock tower post it up. I'll measure the ITBs and take that into account when setting up the thickness of the adapter. I'm hoping to keep it as slim as possible since it doesn't necessarily have to house injector bosses. If someone wants injector bosses I may have to stretch it out a bit if spacing becomes an issue. I'm thinking I can restrict it to 2-3 inches thick. If you check out the pictures of my adapter you can kind of get an idea of spacing. The ITBs may end up about 2-3 inches closer to the shock tower. In the AE there seems to be quite a bit of room, so I'm assuming the S-series chassis would be about the same. FWD cars I have no clue.