Home Made Plenum (Comments Wanted)

[horndog]

I have knocked up a mock up of a plenum that I am going to build and I wanted to ask you guys for comments on any issues that I may encounter with the current design. Plenum height is 75mm.

Final construction will be aluminium.
You will see the mock up has not got the intake hole drilled.(I am still undecided about whether to come out of the front or bottom of the plenum.)
1.How far do the plenum to throttle body tube protrude from your plenums?
2.What other fittings will I need other than BOV and boost pressure sensor?
[attachment=3270][attachment=3269]

[Legend]

Mate, if it fits under the tank it'll work fine.

With the the lenght of the runners, make sure you have enough to get a good grip on the hose.

Make sure you can get the plugs out without removing the plenum.

Leonard.

[AntsBuza]

Test fit with what you have first.
Looks like it mite be a bit wide.

Took me 3 goes to get mine correct.

[Maj]

Throttlebodies are not central under the tank,you will have clearance issues with that plenum but otherwise it looks fine.
spigots /ram tubes need to be like the std ones and trumpet shape into the plenum
you only have ~100mm total space , a little more if your very exact to tank shape , so your spigots can only be 25mm max , 19mm is about the min
this is one i'm using now, in early stages.

[horndog]

Throttlebodies are not central under the tank,you will have clearance issues with that plenum but otherwise it looks fine.
spigots /ram tubes need to be like the std ones and trumpet shape into the plenum
you only have ~100mm total space , a little more if your very exact to tank shape , so your spigots can only be 25mm max , 19mm is about the min
this is one i'm using now, in early stages.

Thanks for the comments, Im thinking that maybe taking it down to 50-60mm height may be the way to go but had concerns about restricting airflow.

Is it proven to be beneficial to use curved walls on the plenum over right angles?

I will take 10mm off the sides as well. Once completed and proven to fit, I will post CAD drawings for anyone else who may want some reference material for their own project.

[Maj]

Throttlebodies are not central under the tank,you will have clearance issues with that plenum but otherwise it looks fine.
spigots /ram tubes need to be like the std ones and trumpet shape into the plenum
you only have ~100mm total space , a little more if your very exact to tank shape , so your spigots can only be 25mm max , 19mm is about the min
this is one i'm using now, in early stages.

Thanks for the comments, Im thinking that maybe taking it down to 50-60mm height may be the way to go but had concerns about restricting airflow.

Is it proven to be beneficial to use curved walls on the plenum over right angles?

I will take 10mm off the sides as well. Once completed and proven to fit, I will post CAD drawings for anyone else who may want some reference material for their own project.

Ping Geri (member list pg 8)
He has a CAD for a plenum
The RCC and Velocity plenums are only 50mm high, no flow probs with them, mine are 60 as thats the size pipe i split for the ends
Don't think the wall shape is worth much besides looks, my first was a 75mm box with tapered ends made from steel , worked fine, seen others with a 75mm tube same results

[Geri]

Ping Geri (member list pg 8)
He has a CAD for a plenum
The RCC and Velocity plenums are only 50mm high, no flow probs with them, mine are 60 as thats the size pipe i split for the ends
Don't think the wall shape is worth much besides looks, my first was a 75mm box with tapered ends made from steel , worked fine, seen others with a 75mm tube same results

Sent some drawings. The shape looks ok, but you gotta thin the gap between the sides and the edges of 1 and 4 spigots. That mock-up looks too wide for the tank.

[horndog]

Ping Geri (member list pg 8)
He has a CAD for a plenum
The RCC and Velocity plenums are only 50mm high, no flow probs with them, mine are 60 as thats the size pipe i split for the ends
Don't think the wall shape is worth much besides looks, my first was a 75mm box with tapered ends made from steel , worked fine, seen others with a 75mm tube same results

Sent some drawings. The shape looks ok, but you gotta thin the gap between the sides and the edges of 1 and 4 spigots. That mock-up looks too wide for the tank.

BIG thanks to Geri for the drawings, also checked out his site which has some awesome pics and detail of his turbo build.
http://peterrimmer.myby.co.uk/busaturbo/busaturbo.htm

[AntsBuza]

Mines all square edges.
No problems with flow.

Shoot me your email and I can do some sizes for you if you like.

[AntsBuza]

pics

[Legend]

Looks similar to mine, Ant.

Seems to work ok on my bike.

Leonard.

[horndog]

Well I think I have the final design, I spent a bit of time playing with it on CAD then printing it out and mocking it up on paper. Managed to make it from 2 pieces so less welding required.
I then mocked it up with tin and put it on the bike and it fits nice.

[attachment=3318][attachment=3317]
[attachment=3322][attachment=3320]

Just got to organize the final aluminium manufacture now.
Thanks for the input from everyone.

Once I get a turbo I will start on the headers.

[horndog]

spigots /ram tubes need to be like the std ones and trumpet shape into the plenum

So you used 53/54 mm pipe to mount to throttle bodies? How did you make the trumpet shape?

If I dont run a trumpeted end will the air flow be disturbed or something?

Spoke to the guy today about the trumpeting and he thinks it may be difficult to flare the end.

Has anyone used 51mm pipe for the plenum and then run a silicon reducer from throttle bodies to the plenum?

[Legend]

spigots /ram tubes need to be like the std ones and trumpet shape into the plenum

So you used 53/54 mm pipe to mount to throttle bodies? How did you make the trumpet shape?

If I dont run a trumpeted end will the air flow be disturbed or something?

Spoke to the guy today about the trumpeting and he thinks it may be difficult to flare the end.

Has anyone used 51mm pipe for the plenum and then run a silicon reducer from throttle bodies to the plenum?

Looking good.

Leonard.

[Maj]

55mm od is an odd size so i use 60mm tube, cut it in 50mm lengths and have the local exhaust guy flare it with the same tool they use on cars for the tapered exhaust fittings onto the std cast manifolds.
then split it and reduce it to the size i need.
The one i pictured above is the only one i have welded to the floor like that, the rest are a free standing tapered tube .
Here is a pic of a McXpress test plenum