UPDATE: 5/7/12 - Finally got around to updating this thread...With completely changing my set-up this is just one of the many parts that was being made and fabricated so like everything else it took a little time. It came out looking much better than expected. Like I said, I completely changed my entire set up so I cant really say that this drives better with the intake/throttle body but since i've been driving it around on the base map it feels really really good. (could be the sidewinder and better turbo lol but i like to believe its the intake) Gets tuned in 3 days so i'll keep this updated.
UPDATE: 3/3/12 - Came across some little velocity stack looking peices in our shop. Gonna attempt to use them on the manifold. Check out the new pics at the bottem! comments/thoughts/suggestions...
UPDATE: 2/14/12 - After this project sat around for a while I decided to get back on it while i'm waiting for manifold and turbo to come in. Honestly don't know how much better this is gonna be over stock but im not going for huge numbers so I don't think there is anyway it will hurt me. We'll see.

Curious if anyone has ever made there own intake manifold. Any advice from someone with experience would be great!

This idea came about when I found the perfect piece of aluminum for a intake and then remembered that I have a spare s2k manifold laying around. Im thinking cut the runners off the stock manifold and welding those to the piece I found. Not exactly sure how i'm going to rig up the IAC yet though. Might be easier to get a different bigger throttle body w/ 4 bolt flange and weld onto. The EGR wont be necessary cause i've got AEM. IDK, just throwing ideas around right now.


Cut the runners off




Put a slight angle on for the ending.

Came across a Wilson 80mm throttle body. Should be able to run IAC off of that with Mustang sensor as well as Using a Mustang TPS...should be no probleming calibrating in the AEM. Wiring up everything is what im dreading just because im not sure exactly what to do yet.

Making a flange for it to fit the huge plenum


Did a slight port/polish on the runners...probably wont make a difference but couldn't stand how ugly it looked lol


Looks like it should fit pretty well..

Cut the plenum

Cleaning out the shop, found some little velocity stocks that I think with a little work should fit perfectly! (not sure how much these things cost?? but was another AWESOME find) If they don't fit then no big deal, back to plan A without them.


Was able to start on the velocity stack install, at first I didnt think it was gonna work at all due to how unprecise the bits i had on the drill press was. But somehow it came out really really good. Really surprised that the rigged up little set up I used worked so well.


Co-worker did all my welding for me

He's pretty good lol

Double checking everything after welding

Making sure the hood would close with the throttle body on :/

Looking like everything should fit just fine

How the vacuum fittings look right before the final install (forgot to take pics of these earlier in the build)

Installed. Finished product.


The new set up

 

Port and use v stacks for the runners as well. You can get a variety of billet TB flanges, I wouldnt use a stock TB. That D Plenom is usually sold by the foot. Good find if it was just laying around.

 

Bypass the IAC valve and you won't have to worry about it... Cool idea, have fun!

 

I would cut the flat part off the D plenum and weld it to the stock runners. Then you can get in there with a die grinder and an aluminum cutting bit and put a nice radius on the plenum floor. Then weld the rest back on it. That will also help with the warping issue your going to have if you try to weld that straight on the rigid D plenum.Also remember that for each 1.75" you cut off the runners you will raise up the resonant frequency that determines your power band by 1000rpm.

 

Why would you want to bypass the Idle control valve?

 

A bunch of S2000 owners have been experiencing stalling issues, and there seems to be no guaranteed fix. One of the many solutions that has been suggested is to bypass the IACV. Several of us have tried it. Some claimed success at fixing the stalling problem; others didn't. I've had mine bypassed for a couple of months and honestly it's had zero effect on how the car behaves. There are threads on this in one of the other S2KI sections if you want to see pics.

Anyway, my point is that if I was building a custom intake manifold I wouldn't waste my time thinking about the IACV. Just leave it off unless you find a specific reason to retain it.

 

I've never had that problem on a car with properly tuned idle controls...unless the iacv was just down right not working.

 

If you notice in the picture the first runner is going to be about normal length and the other 3 are gonna get cut a little short....what's your thoughts on this?

 

Bypassing the iac doesn't sound like a very good idea....I am on aem but you don't think the car would idle strange? Or possibly different with temperature?

 

Slowly starting to make progress on this. Started on my lunch break today