Phat KA-T Santa delivers a shweet intake mani for KA!!!!

[nr2134]

I decided to stop by PhatKA-T shop today for the hell of it, but Ivan had a surprise for me. My intake mani for the KA was almost complete. Its still needs to get welded and polished, but I think you guys will be able to tell that Ivan is not messin around. This will be the same intake mani that Ivan and I will be running, but I called dibs on this one first and Ivan is gonna wait :P(*Has a kung-fu grip on the mani)This will not be a sub $1000 intake manifold. Its a mani for HP freaks like me, but there will be a sub $1000 option coming soon. Ivan will be testing the mani soon and Im sure he will share the info as soon as he gets it....like always.

Well here are the pics. ENJOY!!!!!!

[slide240slide]

Wow looks awesome!

[Redline240]

Amazing....simply amazing....good work ivan!

Redline

[nr2134]

Yeah he did a good job. Its not even finished yet....thats the scary part.Ok I got wood from the pics......got to go.....

[ArticDragon192]

That looks really good. Can't wait to the the finished product and the gains you get on it.

[jacob360]

That thing is beautiful.

[NX95240]

i want one....

[nr2134]

i want one....

I got one..... Its in a Lego stage, but I got one. Dont worry there will be more made like I said. Full race like this one and a cheaper version which is next.

[Ebanks]

I have a testicle in my throat! I mean a lump....not one that needs to be checked!

[Ebanks]

I'm not in the army!

[fiznat]

Wow nice looking! Cant wait to see the final product!

Is this setup for idle air control or PCV?

[NateDogg]

Well done Ivan and congrats nr2134! It looks like a very solid design. Nice to see an ENGINEERED piece rather than a NICE LOOKING piece. Although if this performs as well as it looks the competition will be in deep trouble.

I predict max hp to be at 7200rpm. haha any other wagers?

[nr2134]

Wow nice looking! Cant wait to see the final product!

Is this setup for idle air control or PCV?

IAC will be on the TB and the PCV will be running through the catch can. Since this is a race mani and the car is running EMS it wont cause any problems. The street mani will be more stock ecu friendly.

Well done Ivan and congrats nr2134! It looks like a very solid design. Nice to see an ENGINEERED piece rather than a NICE LOOKING piece. Although if this performs as well as it looks the competition will be in deep trouble.I predict max hp to be at 7200rpm. haha any other wagers?

Thanks, but Ivan deserves all the credit for the work. I just stop by once in a while and steal his smokes and go home.With the cams that Ivan got a hold of and the mani it might be higher than 7200rpm. Both of our motors are built for maximum punishment so we will push it to its limits. I just want to drive it through summer and come Sept or Oct its max hp time.

Who says the competition is not in trouble now.


Modified by nr2134 at 12:40 AM 12/24/2004

[lovenismo]

That looks impressive. Well see how it does when its on and flowing. Great Job guys.

[TrunkMonkey]

VERY nice work.

will the street version allow the battery to stay in the stock location?

-demetrius

[IvanAtSPRacing]

Thanks guys. A LOT of research and design went into this manifold. All variables were carefully considered in the design of this manifold to maximize the performance potential. Basically this manifold will be the highest flowing manifold ever created for the KA application.

Plenum volume and shape were carefully designed to maximize performance. Notice the lack of 90° edges on the manifold (with the exception of the plenum wall to floor) which promotes smooth air flow and distribution with no dead spots at the corners. Any time there is a hard corner it hurts manifold performance, not to mention what it will do to wet flow in those corners if your spraying a wet kit or using H2O / alchy injection. I am actually still considering machining the plenum floor to incorperate a radius to eliminate ALL the hard right angles.

The taper on the plenum accounts for the lack of volume needed as each runner consumes volume from the intake charge as it travels towards the back of the manifold (towards #4 runner) This promotes more even air distribution to all the runners. On the flow bench with our similarly designed MKIV Supra intake, we had less then .1% difference between ports

Runner placement in the plenum is critical for performance. Helmholtz tuning shows that if a runner is placed too close to the ends of the plenum, those runners will end up acting like they are actually longer then they are. The sonic waves traveling back and forth in the runners chage the power band and having mismatched runners is a no no. The rule of thumb is the plenum should extend 1/2 the runner diameter and spacing past the end runners.

The runner inlets are round which is the ideal shape for the best flow into the runners. The plenum floor is also machined with the IIR (ideal inlet radius) which basically creates velocity stacks built into the plenum floor.

The runners are effectivly tapered by changing the shape from round to oval to match the intake port on the head. By tapering the runners this will speed the velocity of the intake charge as it enters the head producing more power.

Runner length was chosen for the displacement of the motor and the power band we are shooting for (keeping helmholtz tuning in mind)

There is still a lot of design and fabrication left for this full on race style intake manifold. As usual, the knowledge gained from our racing products will be carried over to our street products including our soon to be released street intake manifold.

There is alot more to building an intake manifold than a large plenum and some tubes.

[S14tat]

wow i never knew there was soo much science involved in making one of these things.

i mean i saw some of trueleo's MR2 turbo custom manifolds, and he didn't even describe half the steps you went to make one. all he shows is before and after cfm's compared to stock.

well can't wait to see what this bad boy can do man. keep up the excellent work. so far you are the King of KA-T's.

[nr2134]

Ivan and I were tinkering with the idea of a intake mani before Ivan made the exh. manifold. I think the stock mani is holding alot of people back from some good #'s and pretty much any design of an intake mani will make more hp. You can even put a bunch of runners into a pepsi can and it will work better than the stock design. Just because it flows more than stock it doesnt mean a thing. There is alot more variables to consider than just flow #'s. Like making sure all cylinders get the same amount of air.You cant just make a rectangular plenum and put the runners into it without having the right design and expect it to perform perfectly fine.

You will prolly make more HP than stock, but what if one of your cylinders runs a bit leaner than others. Unless you run EMS you wont be able to compensate.So yes, there is some science involved. Otherwise I would of had an intake manifold made a long time ago.

[Kr0n1k]

Ivan, seeing that race manifold has already got me saving my pennies for the street version. Absolutely gorgeous craftmanship, can't wait to see the finished product. Oh, what will the difference be between the race and street version? Emissions?

[Kr0n1k]

Sorry, for the multiple post, one more question, what throttle body will the manifolds accept?

[WDRacing]

Pretty good idea using a thick flange to work the runners into the head. Good way to keep the velocty up.

The runners look a tad long to me, but I'm not looking for power under 5500.

Lookin Good Ivan...as usual.

[Florida240sx]

Must have....You take cash? My project is fixing to start up agian and will be finished before college with ease. Now that I'm getting my old job back going to send my block off and have it built. Excellent work indeed.

[574-240sx]

Very nice. Looking foward to the street version.

[IvanAtSPRacing]

Pretty good idea using a thick flange to work the runners into the head. Good way to keep the velocty up.

The runners look a tad long to me, but I'm not looking for power under 5500.

Lookin Good Ivan...as usual.

Thanks WD.

The thick flange worked out well. Most of the factory hardware can be used for the install (the two long bolts wont work but you wont need to pull the studs out of the head) The transition into the head worked out well. I was able to cut the port angle in half in the flange and then in half again with the runner position to try to keep the transition smooth. The ability to mount the injectors and fuel rail off the flange worked out well also. I like the idea of some beef holding the rail in place. The mounting flange still has a lot of machining left to be done. I am going to counterbore the flange for the runners which will bring the plenum a little closer (the plenum floor is already c-bored for the runners) Once everything is worked out, the flange will be machined to reduce its weight and make it look super pimp.

The runner length was chosen for upper end power based on Helmholtz tuning and others experience with stroker 4G63s. The runners are 5" with 1/8" C-bore on the plenum floor and probably 1/8 to 1/4" into the 1" thick flange so total lenght will be about 6" when you add everything together. Only dyno testing will tell at what RPM this mani will end up helping out the most. If you look close, you will see that the runners make the full transition to oval 1" from the end of the outlet. This does two things. One, it allows the increase in velocity to be finished prior to the fuel injection point which will allow fuel to stay suspended in the intake charge. And two, it will allow me to shorten up the runners if I get the urge and see how it affects the power band.

[egan]

wow, looks amazing! im envious of you guys

quick questions....

-what size throttle bodie are you planning to use?

-what are you going to do about the front part of the mani where the coolant comes out the block through the manifold with the coolant temp sensor and what not?

also, do you know anywhere i can read up in intake mani design? this is really interesting.

[IvanAtSPRacing]

Wilson Manifold 3" TB is what is pictured. That is probably the size I will end up with on my car.

In the 6th pic you can see on the back side of the mounting flange where the shape of the water outlet port on the head has been machined half way thru the flange. As soon as the elbows I ordered come in, I will figure out where I will mount the elbow and how I will continue the water passage thru the mounting flange.

http://www.grapeaperacing.com/GrapeApeRacing/ for technical info that will make you wish you had applied yourself in math class a bit better

[Redline240]

What size pipe did u use to make the pleneum Ivan? And have you measured the volume of the entire manifold?

Redline

[racingdc9]

Ivan,

VEEEEEERRRRRRRYYYYYYY nice. $1000.00? will you take an installment plan? hehe $100/month for 10 months

[WDRacing]

I still think I'm just gonna build a cheap intake from sheetmetal. Just to see get an idea of head flow and whatnot. The stock intake is suck a restrictive pig I'm almost gauranteed to make a little HP. I was actually thinking of using plastic, If I could only find the supply for it.

[IvanAtSPRacing]

I still think I'm just gonna build a cheap intake from sheetmetal. Just to see get an idea of head flow and whatnot. The stock intake is suck a restrictive pig I'm almost gauranteed to make a little HP. I was actually thinking of using plastic, If I could only find the supply for it.

HAHAHA... I think WD is CRUNKED... Are you still buzzing from a Christmass even Egg Nog festival? I just read a couple posts from you and either your really tired or you are feeling the effects of and alchy binge Your missing words or have too many... I cant tell. I think I understand what your saying... but let me get another beer in my system and see if it makes more sense.

Just kidding with you WD.... You know I respect you.