I started a thread many a year ago theorizing a better intake plenum. After a few failed attempts at hand making the prototype I have finally acquired a tool to help me make this a reality:

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The printer is small so everything is printed in pieces and reassembled via epoxy, but it's been hugely successful thus far!





Below is the first of a set of 48mm velocity stacks that will go inside the plenum.

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This design should improve flow across all runners and the capacity of the plenum has been specially calculated for higher boost. The stacks are made from standard PLA and will be wrapped in carbon fiber for strength. I will test with the wrapped parts first, this is a process that has been used on other 3D printed parts PLA plastics so it should not be an issue. Worse case, it becomes a plug for a full CF or kev/CF sandwich.



Here is the 3D model I'm working on:

Plenum (lower) w-o stacks.png

Plenum (lower) bottom.png

v-stacks.png

Plenum (lower) with stacks.png



The model for the upper plenum is not complete yet obviously, but is and example of what is to come:

Plenum (upper) incomplete.png



3mm rubber o-rings will help seal all components from gaps or leaks. Then shorty 48mm runner will connect to GSX-R TBs gracefully borrowed (stolen) from Blitz's R&D.



More updates to come, but I still have some calibration to do on the printer. Hopefully by month end I'll have all of the v-stacks and the lower plenum half printed. I'm going to invest in some more tools to help the CF process go over a little better than the speaker box build. But exciting times ahead!



As always feedback, suggestions, claims of witchcraft?

(Be nice or I'll scare up those dreaded maths again)

 

I suggest you make a printer capable of the whole thing in one whack. Press "Okay" and come back a week later to a finished part!



Other than that, just a wish for good success.

 

Sadly the print size is something I am stuck with for now. After I see a few prints and get regular business the plan is to invest in this unit:







That aside it looks like I have found a better method for the body of the plenum and runners. Since heat is a concern and after working to calibrate the printer I have found the temperature range of the print head and ways to print with better materials. This will take some practice but if this goes right I can print in carbon reinforced ABS which is much stronger. This will allow me to produce a permanent negative of each side for easier one piece that alleviates the current concerns of melting.



Obviously there is a pretty decent learning curve to all of this but every day this becomes closer to a reality! Hopefully I can update this soon with at least one finished CF product.

 

That's friggin sick man! I've been dreaming for years it would amazing to be able to make my own parts. Good luck! I'll be following this closely. Keep us posted with your progress!

 

Keep up the great work brother

 

This is awesome. I hope it goes well. As soon as I'm happy with the 3D printing technology that I can afford with a large enough build envelope I plan on getting into these sorts of projects also.

 

Progress has been slow on this project as of late due to much needed home improvements. I have the printer calibrated finally and after a few more test prints I'll be ready to test with a fresh spool of ABS. ABS will allow the vapor process to melt the edges into a smooth curve that I can work with.



I have some new vacuum equipment on the way as well and once I have that cracked I'll be ready to start with the CF version. For now I am working on getting the software to flow test the render vs. what is already known about the stock plenum and Airram. I also plan to build a fiberglass demo unit for various other tests and fitment.



Once the TBs arrive final measurements will be made and modifications to the design complete. Then printing may begin!





All said and done I am going to test thoroughly to ensure that the plenum will hold pressures far in excess of what the turbo will provide and will flow far better than the stock unit, and if possible better than the Airram (uphill battle, but that's what goals are for.)

 

The TBs finally arrived!!

TBs came in the mail.jpg

specs: 2002 GXS-R 1000





All measurements done.

itb flanges.png

Head size is based on the pnp planned for the head (.5mm+/- removed to improve on the shitty casting). I am going to try to fashion a cm spacer between the TBs so I can run them strait without bends for nice even airflow through out all ports.





I am still not certain if I am going to remove the SVTa butterfly all together or just make a gear to open both simultaneously.

 

Some shots of the final plenum after all measurements. Obviously I still have to add the bungs for the IAC and the vacuum, but this is a representation of what to expect.



Adapters 2.pngAdapters.png



Plenum bottom2.pngPlenum bottom.png



Plenum top.pngPlenum top2.png





I am installation flow simulation software and hope to have that diagram shortly.

 

Christmas is coming brother so I hope you send me one of these