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BP ITB/Stub intake manifold

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    BP ITB/Stub intake manifold

    These have been a LONG time in the making for me. Since my acquisition of the CNC router, things become significantly quicker and easier to make that have complex geometry. I took the models I made back in 2010 and loaded them into my CAM software



    Here you can see the machine has finished the roughing pass, and is working on the finishing pass



    One half of the runners needed, need 8 total of these. Each group of 4 takes approx 4 hrs machine time



    All 8 runners cut, with flanges mocked up



    Skipped a few steps but here's the mostly finished pattern. Gussets have been added between the runners and fillets/radii have been added where needed



    Here's the CNC cutting the corebox, these 'mold' the inside of the runners. Corebox was approx. 3.5hrs machine time



    Finished corebox with one core in the foreground, top half of the mold in the back



    Bottom half of the mold with 3 of the 4 cores set in place. The assembled mold weighs in nearly 300lbs



    ~10lbs or so of molten aluminum, waiting for it to cool to hit the correct pouring temp. 1325°F seems to do the trick. The mold only takes 6lbs or so I had a few other things to pour



    Skipped pics of the pour and shakeout because it was late. Cut the gating off but here's the raw casting prior to machining





    The head ports match the gasket size, so they're larger than a stock intake manifold. The other end is 2.2" OD with a ~1.8" or 46mm ID suitable for GSXR1300 throttles, or runners and a plenum could be welded to the stub to make a complete traditional manifold.

    The BP port spacing also matches the DCOE standard, so by adding a wooden flange to the pattern it would be possible to cast these with twin DCOE flange instead of an open end. To this you could bolt twin dual side-draft carbs or Jenvey or similar throttles

    More pictures to come once this is machined!
    -Rocket
    Last edited by Rocketman; 04-13-2014, 12:56 PM.
    1991 Capri XR2 "GTXR2" BPT AWD Bastardization/conversion
    1991 Isuzu Impulse RS Turbo AWD

    Creator of the B6T Rocketchip
    www.werbatfik.com

    #2
    Amazing work yet again!!! stoked to see this as a fully machined beauty
    ---Has ClubProtege helped you in someway? show your support by Contributing--- Click Here---

    1992- project FE3..... 313 WHP @ 9.3psi




    I pet my dash when I get into the car..."good car"
    he actually has a mazda tree, parts grow on it

    Comment


      #3
      Very very cool. Thanks for sharing!
      Ian Boyd- Bellingham, WA (click vehicle to view)

      1988 BF GTX

      1990 x2 BG AWD Protege

      1991 Escort GT- SOLD

      1975 911 S Widebody 3.6 conversion

      2005 Corolla

      Comment


        #4
        Great work man. You are a very talented person.
        Cincinnati, ohio Bengals for life
        "Who Dey"

        Comment


          #5
          Very nice work! I'm looking forward to seeing the finished product.

          Happy Motoring!
          02 DX Millenium Red - The Penultimate Driving Machine
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          Comment


            #6
            Matt can you also flange those for the MZR?

            Comment


              #7
              so how much?

              Comment


                #8
                Clay, I could make one for the MZR but it would need a whole new pattern built, bore spacing/port size is going to be different and there's no adjusting that once the pattern is made.

                I have to finish machining it before I can determine a price.





                I got it milled flat, still need to make a jig on my CNC for drilling the bolt holes.
                1991 Capri XR2 "GTXR2" BPT AWD Bastardization/conversion
                1991 Isuzu Impulse RS Turbo AWD

                Creator of the B6T Rocketchip
                www.werbatfik.com

                Comment


                  #9
                  cool

                  Comment


                    #10
                    absolutely amazing work man!
                    -Jack

                    ONTARIO MAZDA CLUB! Join! https://www.facebook.com/groups/500055016671733/

                    91 626 LX - basically stock and pretty slow still
                    http://www.clubprotege.com/forum/sho...my-GD-626-LX-)

                    01 E53 3.0i - FOR SALE! pm if interested

                    91 USDM Protege LX - SOLD! turbo/manifold up for sale!
                    http://www.clubprotege.com/forum/showthread.php?t=46606

                    Comment


                      #11
                      Updates! hah. My flange blueprint I made years ago turned out to be a little off (bolt hole spacing) luckily I caught it before drilling into the piece. But it took a while to re-measure the flange and make a new jig.

                      Here's the mostly finished manifold, with my drilling jig:



                      The jig auto-located & centers itself using the ports, and allows me to drill the holes quickly on the drill press without sacrificing any accuracy. Drilling on the mill with the digital readout/coordinate system is super tedious

                      The lower bolt holes are a little close to the runner radii on the flange



                      I should be able to run an endmill over this and clear some material away. the runner walls are plenty thick.
                      1991 Capri XR2 "GTXR2" BPT AWD Bastardization/conversion
                      1991 Isuzu Impulse RS Turbo AWD

                      Creator of the B6T Rocketchip
                      www.werbatfik.com

                      Comment


                        #12
                        Super badass. So do you have a CAD file that you could pull measurements from? I may have already asked lol.
                        Ian Boyd- Bellingham, WA (click vehicle to view)

                        1988 BF GTX

                        1990 x2 BG AWD Protege

                        1991 Escort GT- SOLD

                        1975 911 S Widebody 3.6 conversion

                        2005 Corolla

                        Comment


                          #13
                          I had to measure a factory manifold & made my own CAD file with those measurements. The first file I had was off by less than 2mm but would be enough to cause a fitment issue.

                          This time around I threw the manifold on my mill & used the probe in the spindle, and DRO/coordinate system to log each datapoint. This is more accurate than trying to measure everything with a pair of calipers lol, errors can't build up
                          1991 Capri XR2 "GTXR2" BPT AWD Bastardization/conversion
                          1991 Isuzu Impulse RS Turbo AWD

                          Creator of the B6T Rocketchip
                          www.werbatfik.com

                          Comment


                            #14
                            one hell of an update!!! product looks great!
                            ---Has ClubProtege helped you in someway? show your support by Contributing--- Click Here---

                            1992- project FE3..... 313 WHP @ 9.3psi




                            I pet my dash when I get into the car..."good car"
                            he actually has a mazda tree, parts grow on it

                            Comment


                              #15
                              Is anyone interested in this piece? I haven't touched my BP car for quite some time, and it's not looking likely that I'll ever get around to fitting this. I don't really plan on making any more at this point. Either way it's sitting on my shelf collecting dust. If you're interested in it PM me
                              1991 Capri XR2 "GTXR2" BPT AWD Bastardization/conversion
                              1991 Isuzu Impulse RS Turbo AWD

                              Creator of the B6T Rocketchip
                              www.werbatfik.com

                              Comment

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