new 1ZZ manifold

[Subxsonic]

now its time to show you some pictures of my project.
http://img192.imageshack.us/img192/1198/toyorgboegenflansche.jpg
on this pic you can see the original 1zz-fe piping. (the airbox is already finished)
a lot of work to creat a 1:1 model with CATIA V5 R19
on friday i`ll simulate the cfd and use the result to optimize the piping.

in 2 weeks i`ll finish my project and a friend of mine produce the first prototype. ;)

[Boosted Yotaman]

I wish I had the programs and knew how do do this stuff. Thats cool though man. Good luck!

[jin602_05]

nice! can't wait to see the result. :)

[Subxsonic]

the big challange was, that the original manifold is a extruded plastic part with diverse geometrics. this is my 3rd gen and i`ve invested over 70h to create the final parts. now i have the skills to create all gemoetrics i want. ;)

i want a evolution of this manifold:

on first step i observe only the static airflow, and enhance the original manifold with the same piping lenght. i `ll eleminate the restriction of the original part and increase the max massflow rate by using the max. available place.

the next gen is a complete new manifold. with new piping lenght to control the max torque or engine performance.

i`ve calculated all the piping for this camshafts
-stock 1zz/2zz
-crower (all)
-piper
-dbilas


but for the final last gen i must simulate the gas cycle. i need the dynamic results of the piping resonance pressure charging.

at the end i`ll have 5 manifolds:
-1zz stock enhance
-1zz N/A upgraded (only for Crower stage 2 "N/A")
-1zz turbo manifold

and for my friends
-2zz stock enhance
-2zz N/A upgraded

[Shizuma]

Looks nice. I've been using Solidworks to make my manifold, I'm nearly ready to shell out the prototype. Looking forward to seeing what you come up with.

[Subxsonic]

-which piping lenght do you use? the original or your own one? static analysis or static + dynamik analysis?
do you use the cfd plug in of solidworks? i use STAR CCM+ http://www.cd-adapco.com/products/STAR-CCM_plus/. i love this programm. with the macro function you can create multiple simulations and save a lot of time and compare all results
recording my macro: 1,5h
reuse: 30sec ;)
at friday i simulate 5 manifolds. each pipe with the airbox and for my end presentation the complete airbox.

[Shizuma]

-which piping lenght do you use? the original or your own one? static analysis or static + dynamik analysis?
do you use the cfd plug in of solidworks? i use STAR CCM+ http://www.cd-adapco.com/products/STAR-CCM_plus/. i love this programm. with the macro function you can create multiple simulations and save a lot of time and compare all results
recording my macro: 1,5h
reuse: 30sec ;)
at friday i simulate 5 manifolds. each pipe with the airbox and for my end presentation the complete airbox.

I'm using my own length, both because of packaging constraints as well as system setup (turbo, ITB). I used dynamic analysis with both steady stream and firing order flow models at 1 to 20 psi using the solidworks model. I'm looking forward to seeing what plenum design you go with as mine is a bit...odd lol.

[edg3h_91]

oooOOoO keep this updated

[horty222]

Those are great design products. Solidworks gives you a lot of options and good 3 d modeling.

Awsome job man. Im impressed.

[Subxsonic]

@shizuma: where is your problem? it`s much easier to creat a turbo manifold as a regular manifold. your dynamic come`s from the charger.

1) inlet piping short as possible. REALLY short.
2) inlet piping straight as possible
3) a small plenum.

here we go ;)

please send me a pic from your plenum.

[Shizuma]

@shizuma: where is your problem? it`s much easier to creat a turbo manifold as a regular manifold. your dynamic come`s from the charger.

1) inlet piping short as possible. REALLY short.
2) inlet piping straight as possible
3) a small plenum.

here we go ;)

please send me a pic from your plenum.

Oh I know it would be easier, but I'm bored and hopefully the prototype will net me some of my off boost response back. I'll send you a pic of the plenum in a second.

[JSPITZ]

nice work Can't wait to see the actual prototype

[BlueCrush]

Very interested in this. Also, checking into a 2zz-to-1zz Intake Manifold spacer to use a 2zz stock IM on a 1zz. But this might be the better route if it is specifically made for the 1zz. I'd want the -1zz N/A upgraded (only for Crower stage 2 "N/A"). Any ideas on pricing yet?

[zzt231 gr]

Very interesting!!Subscribed!

[Subxsonic]

the price depends how many people finally want a manifold and how high is the shipping to america from germany (but this is a minor problem). i think i get a good price if i`ll order 10 or 20.

material: aluminium
stainless steel isn`t alternative solution (1/3 more weight) and carbon fiber is to expensive. (2000

[Subxsonic]

http://img709.imageshack.us/img709/9391/catia3.jpg
http://img85.imageshack.us/img85/903/screenstarpresim.jpg

2 new pics

[Subxsonic]

Igor.......IT`S ALIVE!!!!!!

A lot of work, but it`s finally done. Enjoy!

http://img96.imageshack.us/img96/1156/schnittebeneshort.jpg
http://img705.imageshack.us/img705/8219/simulationstaubereich.jpg
http://img580.imageshack.us/img580/7567/streamline1short.jpg
http://img375.imageshack.us/img375/4497/streamline2short.jpg

[evilthorne]

What would it look like with all four runners in place. Keeping in mind that only one is really drawing air at a time.

[Subxsonic]

i`ll post the rest of my pics in the next days (incl. the complete manifold and the real massflow).
this pics are only examples.today i finished my simulation macro (all physics and continuas i need). now i save a lot of time. i need only the part, load my macro and after 20sec i can start my simulation. (without my macro i need 30min for this work)

i`ve calculated the massflow of my manifold and measured the massflow of my celica with my obd2 software. the next step is a simulation table for my macro. with this table i can create a dynamic time-discrete simulation. 800rpm up to 7200rpm.

[johny123456]

can't wait for it to be finished.

[BlueCrush]

can't wait for it to be finished.


x2.

Wow!! This is Awesome!!

[Subxsonic]

Here is a small calculation example (the reason for a new manifold for my crower cams)

1) Stock 1zz cam:
for example 4400rpm
ES= 55

[Boosted2.0]

Just a heads up subxsonic - if you desice to sell these you will need to contact larry and sign up as a site sponsor first. Its very inexpensive and you can buy just one or two months of sponsorship initially if you are unsure of making a longer term investment in the community.

[Subxsonic]

@Boosted2.0 : thx for your advise, but i think it`s at the moment to early for sponsorship.
it`s only Alpha status now and i have to do some more work, that i can sell it with clear conscience. if i hold my first prototype in my hand we can talk about it.
(Without FEM Analysis and stress test i won`t sell ONE part)
or is this a problem in your eyes? :confused:

[HiloGT]

great job can't wait to see the finished product

[Smaay]

can you email me the catia file? i would like to look at it.

eodninja6@gmail.com

[dannysgtcel]

Great job on your intake manifold design.hopefully it shows good flow and performance over the stock pos manifold.If it does you can put me down for one.:thumbup:

[Pool Playen Bob]

maybe to expand your markets see if it'll work for MR2's as well.

[RevHard]

It sounds very interesting, I'm in with this too!

[BlueCrush]

It should work on the Matrix, Corolla & Vibe as well.

[Subxsonic]

@ Smaay: Nice try ;)
@ Pool Playen Bob: At first i creat it for MR2, Lotus Elise and Celica.
(After my exams( in the next 2 weeks )i have sparetime again and i measure all engine bays)

this is not my only project for my Celica. (2 exterior, 2 interior and 5 engine projects). step after step i show you my projects. ;)

[RevHard]

So good luck with your exams :thumbup:

[Subxsonic]

thx....14 exams on 6 days

[Subxsonic]

@dannysgtcel: these pics show only the original 1zz manifold, not my new one.

[Pool Playen Bob]

It should work on the Matrix, Corolla & Vibe as well.

right in theory it "should" but clearance's are different in different vehicles. i know what vehicles have 1zz's thats why im saying if you need to change a few little things to make them fit any vehicle with a 1zz with very little or no modifications.

[BlueCrush]

I'm pretty sure the others have more clearance then the Celica.

[Boosted2.0]

@Boosted2.0 : thx for your advise, but i think it`s at the moment to early for sponsorship.
it`s only Alpha status now and i have to do some more work, that i can sell it with clear conscience. if i hold my first prototype in my hand we can talk about it.
(Without FEM Analysis and stress test i won`t sell ONE part)
or is this a problem in your eyes? :confused:

No, not a problem at all. As I said - only necessary once you are ready to sell.

[Subxsonic]

@Boosted: ok, i misunderstood you. i`m sorry. My nerves are on edge in reference to my exams.

[fatalexception]

wow, this looks intense. I kinda dabbled in designing my own manifold for a few hours, before I realized I really lacked the knowledge and a decent 3d modeling software... This looks promising though, definitely gonna subscribe to this one...

Good luck on your exams too, thats a crazy sounding week...

[Subxsonic]

@fatalexception: it`s not only cad. you need to know a lot of additional informations:
- timing of your valves
- pipe length in the head
- massflow
- pressure at your valves (not really necessary but the cherry on top)
- knowledge of fluid mechanics

don`t forget the airbox. the dimension of your airbox depends of your cylinder bore....

[MidnightMac]

any updates?

[Subxsonic]

ooooooh YES......
Since Monday i`m working with the complete matlab toolbox. http://www.mathworks.com/products/optimization/?BB=1 . i`m creating a simulation multi-layer model for perfect calculation of the runner lenghts.Depending on a lot of influences. it`s a might piece of software. :eek: I LOVE IT!!! ok it`s f**** expensive...one license key-->30.000Euro.

now we log a lot of engine data.that i can use for optimization. it sooooo cooool ;)

On Saturday i get the oem 2zz manifold of a friend of mine ;)

[RevHard]

That's souding really great! Keep us posted :thumbup:

[igor cella]

I'm from Brazil and I have a 1zz Corolla with I/H/E and crower stage 2 cams. I'm anxious to see the results and buy a manifold.
Good job

[neekei]

i'm building 1zz on stage 2 cams and really interested in such mainfold.

I have an access to metalworking factory and i can make some goods like this, but i can't make right calculations for it.

I will watch your progress

[RevHard]

Any news pal? :rolleyes:

[djdecember]

hmm...why do u have a big hole on the side of a flat wall? there is turbulence there....why not make the throttle body hole make a smooth transition into a circular or oval tube which would decrease turbulence and make the airflow faster,,,,seems to me in your project air is slowing down when it enters the body before it goes into the runners

[hattrickey]

if this shows gains i'll definitely buy this once your ready to sell

[Subxsonic]

@djdecember: this is the stock manifold, not mine ;)

update: i`m now at the FEM analysis

[RevHard]

Great news!!!

[hattrickey]

any updates on this?

[Subxsonic]

Yes, i changed two times my current design. I wasn`t satisfied with the simulation results. Now it looks really good. I hope i can post you to the end next month the final manifold.

[McGuber]

Interesting stuff. Keep it coming. :)

[BlueCrush]

Nice! Can't wait!!

[jamespocoloco]

when will this be done? :wiggle:

[Subxsonic]

As soon as possible. i`m still waiting for a friend who weld the 3 Prototypes. But he is on holiday the next 2 weeks. :marky:

[jamespocoloco]

ooo well if this a success i want oonnne ^_^ put me on list

[sgenini]

Any updates? :]

[ranger4.ol]

very interesting

[Subxsonic]

sgenini: yes, a new throttlebody and new airfilters. i must test the new filters to see which has the best massflow. [sponsored by a airfilter-compony ;-) ]

[johny123456]

do you have updates on this?

[ano]

up

[RevHard]

I think there's still a bunch of people waiting for this stuff, me included :gap:

[sgenini]

updateupdateupdates?!

[ginobendezu]

any updates? this gives us gt owners some hope for a performance intake manifold

[lajlijthoj]

Be pretty amazing the day I see a fully n/a 1zz 200hp with similar torque numbers.
Shouldn't be impossible, if B18AB18b motors can do it, I'm sure you 1zz owners can do it too. But wouldn't be cheap either.
You guys need something like this-
http://www.nonvtec.com/forums/honda-b18a-and-b18b-engine-modification-guide-t2181.html

[ginobendezu]

why cant we take a DDP 2zz IM, fab tubes that connect to engine, and then weld em on?

[ginobendezu]

look what I foundddd :D http://www.youtube.com/watch?v=KWQ7hXIhAiU&feature=related

[TmanGT]

look what I foundddd :D http://www.youtube.com/watch?v=KWQ7hXIhAiU&feature=related

That's my old project. Haven't touched it in 2 years..

[ginobendezu]

haha no way! THATS AWESOME do you still have it? and are u still thinking about making more? maybe some that look a lot cleaner? i mean it still kicks ass and sound orgasmic but making something more flush for those who also want a clean looking engine bay, kinda like the DD one

also what gains did u get? i saw u dyno'd it but no numbers were given

[TmanGT]

haha no way! THATS AWESOME do you still have it? and are u still thinking about making more? maybe some that look a lot cleaner? i mean it still kicks ass and sound orgasmic but making something more flush for those who also want a clean looking engine bay, kinda like the DD one

This was my original prototype, and very first shot at making anything out of metal from scratch. I will say that the current iteration of this is alot different is design, just hasn't come to fruition due to other priorities and school

[ginobendezu]

very nice, yea i thought it was u, i recognized ur car

[Xtra Big Kahuna]

Any updates?

[kavanaghmtl]

Any updates?


x2:wiggle: