Willie: Yea, it'll be interesting... but when you do the larger throttle body, you have to increase the size of eerything else as well slightly, and definitely do the throttle body port matching... It won't be right away, but eventually, i plan on doing a back-to-back dyno with a stock setup versus this setup... for my own benefit at the very least, i need to know if its doing anything... although, once i dyno the car, i'll know... these cars are pretty consistant on thier dyno results when stock.

Met: I'll be cutting the valve mount out of the back opf the old cast intake piece, and then carefully grafting it in place on the side of this manifold. Then, there will be a hose that runs from the IAC, over to the intake tube for air since the throttle body has no provision in it for any sort of IAC.

Sub-Zero: Eventually i plan on doing the back-to-back test... but not right away, i just don't have the time. THe flares are on hold until i can decide to do something more creative with the setup... the foam thing did not work as planned... it could, but i simply don't want to spend the money on the foam doing trial-n-error trying to figure it out. Maybe sometime in the future... so for now, i'm just going to keep the car at a taller ride height or something... haven't quite decided yet... i've been thinking about just doing it in metal.. cut-n-trim style... lol!

 

Satellite Beach! I was just over there a few weeks ago. Folks live near Bunkys (or what used to be bunky's)

Do you have forced induction? I believe this would be an excellent mod for mildly boosted applications. If I can ever sell my b-series turbo stuff, I'll be boosting the s2000.

 

Really beautiful work, and a great alternative to a full out sheet metal intake manifold. I cant wait to see the dyno numbers. It should help out up high in the RPM range but I cant help but think you will loose some low end torque from it. I guess time will tell.
on innovation.

 

chimmike: Sweet! Yea, i live right down the road from there in Indian Harbour actually... i just moved from Satellite. No, there is no FI yet... but it's on its way for next season

Speedy: Thanks! Yea, i think this'll work decently. I'm less concerned with how it works N/A, and more wanting it built to be ready for when i boost the car. If it gives up a little down low, but gains up top, then i'll be happy wiht that, since we're usually running in the upper range of the powerband anyway But as for low end torque, i'm kind of hoping the extra .2 L will help that out a touch... lol!

 

Nice work I bet it will look very cool under the hood.

 

agreed that you are doing nice work but a flow test on the intake is the only way to verify that you made any improvements. sub-zero is correct that you could try it on the dyno, but back to back testing can be misleading due to the ECU "learning" crap.

edit: and another thing, more air requires more fuel, this ain't gonna be a green ass hybrid fuel sipper.

 

<~~~ running Hondata K-Pro... i.e. there is no such thing as "ecu learning crap" and that also will take care of any additional fuel requirements.

And yes, i intend on doing testing with it, but for the time being, i'm just going to have to wing it... i don't have time to spend a day at the dyno to do a back-to-back... but i will sooner or later




Puddy: Thanks! yea, i figure even if it is losing power, it'll look blingly... lol! kidding.. i didn't change the volume by THAT much, and the virtues of the stock manifold are still intact... only with an added throttle body size difference to aid in getting more air in... how bad could it be?

 

That looks great. I'd like to see how it performs.

 

Time to finish the intake manifold... i still needed to weld on the bosses for the throttle cable, and then install the IAC flange setup so that i'll still be able to control the idle like stock with this big huge TB... it'll be nice to still be able to fire it up cold and have it idle clean...

So, first thing to do was to cut the throttle cable bosses off of the original intake manifold section, and weld them to my sheetmetal setup... On a side note, this is probably the last time i use an original boss setup like this... the cast is just way too dirty, and the welds came out looking like turd because of it... but regardles....




Next up, it was time to do the IAC... so, i cut the IAC flange and everything off of the old manifold, and then also sealed off the original air chamber, and then welded on an AN fitting, since i'll be running a braided line to the intake tube for the clean air source for the idle valve...




And then marked off where it'll need to go after doing some measurements for the coolant hoses and stuff that the IAC uses...




Once cut, i positioned the setup, and welded it in place...












So, that came out clean...

Next up was to get rid of the EGR setup... most people just put a plate over the top, but i wanted it to be a bit more clean than that i guess.. so i decided to chop it all off, and weld the hole shut.








Yea, that looks WAY cleaner

Next up was to finish the setup off, and seal up the original IAC voids that are in the manifold. For this job, i have a very high strength and high temperature liquid epoxy... it is a two part mixture, and seals hard as can be.

The way i did this, was to take a pice of packing tape, and seal the inside of the plenum area... this way, when i pour the plastic, it'll fill the voids, and since the tape is a smooth flat barrier, it shouldn't require any porting at all once done... just peel the tape off, and the inside will be smooth...

Applying the tape: Can barely see it in the pics... darn clear tape.. lol!








Then, i mixed up the plastic, and did the pour...




Then, i removed the tape, and here it is... perfectly smooth:




And sealed off on the outside:




And there ya go... manifold is all finished, and ready to go onto the freshly assembled 2.2L motor...

 

Looks nice! I'd keep an eye on that epoxy over time, it's heat expansion rate might be different enough from aluminum that it may eventually separate. Are you putting a Hondata heatshield gasket on there? (though I guess if you're going F.I. with that manifold it wouldn't really matter)