Another Race-Tech manifold/car parts thread

[Rick]

There last thread got a bit cluttered so thought i'd start another.

Heres a few various pieces. If anybody is still interested in welded pipes.

Honda civic jordan with our B series turbo kit

Bumper was already cut by a previous exhaust shop so we made ours to the cutout they did.

CFD exhaust flow

We had a tight radius to get to the cooler as the customer had a really thick rad meanign the turbo was moved across, we had to piecut into the "backdoor" intercooler

2.5" exhaust

Manifold

 

[Rick]

B series n/a manifold

B series sump (still at the cad stage)

A customers car, Sleeved b16 with precision 6262, our inlet/exhaust manifold will be running 40psi boost.

B series ram horn

Heres a couple of welds, not the best but you can also see the penetration in the bottom right corner.

Inside

An EP3 Exhaust

B series intake manifold

 

[Rick]

A few more bits.

B series torque mount, 0.5kg, (0.5kg saving)

A GT35 manifold for a toyota starlet, 1.3!!

CFD of an inlet manifold, (old design now)

Heres a couple more of a kit that went out today.

 

[Engineer]

Looks very nice indeed................are the bends done with a mandrel CNC machine I wonder?

 

[Burf86]

The B series intake manifold made my heart skip a beat.

 

[tux]

For me, that's bordering on pornography!

 

[chimpface]

Really nice stuff excellent , but one thing , would it not be better to have the pipe going into the exhaust flange almost to the cylinder head face and [ 2-3 mm ] away then tig welding it before flushing it off ? Then the exhaust gas wouldnt hit a big step in its flow . Just a suggestion , but honestely thats some really lovely work to be proud of.

 

[Pete.]

Outstanding work Rick.

What does a Starlet rev to? Can't see it being more than 6 or 7 thousand RPM. Must take some time to spin up that GT35R.

Just a general question. With your CFD software, do you see a huge amount of loss or gain from different designs of plenum, or are gains more marginal? Also, for a parallel-sided plenum fed from one end - does the software show a huge variation in flow from the closest inlet to the furthest?

Not asking you to give away secrets etc but just curious as you see all manner of shapes and sizes of plenums on bikes, and inveriably the builder gives first consideration to fitting in the tight space without knowing if the design is good or flawed.

 

[Rick]

Really nice stuff excellent , but one thing , would it not be better to have the pipe going into the exhaust flange almost to the cylinder head face and [ 2-3 mm ] away then tig welding it before flushing it off ? Then the exhaust gas wouldnt hit a big step in its flow . Just a suggestion , but honestely thats some really lovely work to be proud of.

Hello,

The pipe doesn't actually fit inside the runners. Thats the reason we don't do as you say. The actual cylinder head is the exact same size as the pipes but the flanges are made bigger for the use of custom cylinder heads. In the real world it doesn't actually make a difference. We aren't chasing for every last HP on the honda's they flow so well its easy to achieve massive bhp, we are actually trying to detune them most of the time to keep them in one piece. We have tapered reducers we use on "higher end" manifolds which obviously remove this step and make for a smoother transition. Good points and thank you for the kind words, constructive critism is always welcomed, without that we wouldn't try to improve.

Outstanding work Rick.

What does a Starlet rev to? Can't see it being more than 6 or 7 thousand RPM. Must take some time to spin up that GT35R.

Just a general question. With your CFD software, do you see a huge amount of loss or gain from different designs of plenum, or are gains more marginal? Also, for a parallel-sided plenum fed from one end - does the software show a huge variation in flow from the closest inlet to the furthest?

Not asking you to give away secrets etc but just curious as you see all manner of shapes and sizes of plenums on bikes, and inveriably the builder gives first consideration to fitting in the tight space without knowing if the design is good or flawed.

Hello,

Actually the starlet does rev pretty high, in standard form they rev to over 8000 rpm's. This car revved to around 9 IIRC (we didn't actually do the tuning) I think its the UK's fastest car starlet. The manifold was designed to give the highest possible exhaust speed at maybe a small sacrifice in top end. Spool was actually excellent, full boost around 5500rpm's. Its mainly a drag car so thats a big enough powerband.

On the CFD, we design the taper of the plenum to try and equalise flow the best we can. All the velocity stacks inside are also angled to again equalise flow. As you say furthest from the throttle body gets the most air, so you have to reduce flow to this cylinder if you can to get a more even match. As a tuner this is something I always try and get the most even possible. I often see (today watching touring cars for example) much simpler plenum designs that don't offer a balanced flow these obviously work very well and at full throttle I dare say the difference is marginal but at part throttle I can see a difference in EGT's and AFR's while tuning.

We have a few more idea's to use on future inlets, plenums IMO are about the best compromise as they are now. But the runners "might" be able to see gains, marginal and more costly but its worth exploring.

Heres a few pictures of some more recent work.

I took my 400hp daily driver around the track

Not welding but an engine we've just built for an MR2 (aiming for 700hp)

 

[Engineer]

Parts look lovely..........what sort of BHP, and what classes do the finished cars race in?

 

[Rick]

Parts look lovely..........what sort of BHP, and what classes do the finished cars race in?

Near all of the above are customers toy's and track cars, Not competive.

Power is upwards of 300. The bronze/copper car is a race car, and is the UK's quickest of its kind. It will be upwards of 700hp on its current setup should do 0-140 in around 10 seconds. (drag car)

 

[Engineer]

Real shame they are not used seriously...........but then again if customers are prepared to pay then I guess thats the main thing.

 

[Rick]

Real shame they are not used seriously...........but then again if customers are prepared to pay then I guess thats the main thing.

I don't think we'd get the flexability to run parts like these on race cars. It'd be nice to work within regs though, but "tuning" is part of the fun for most of our customers. A few are used in competitive events.

 

[J_K]

can I ask what program you did the flow visualisations on?

I'm wanting to make a new inlet manifold for my M3 and rather than "thats looks like it should work".. I'd prefer to know it would work.

 

[Rick]

can I ask what program you did the flow visualisations on?

I'm wanting to make a new inlet manifold for my M3 and rather than "thats looks like it should work".. I'd prefer to know it would work.

Luckly I have friends in the industry and can "muddle" along with the CFD programs. If you haven't done this kind of thing before it would take a long time to do a model. I spent around 60hours+ with some help to get the first working model.

Regards
Ricky

 

[tommy dunlop]

stainless manifold

some lovely workmanship there mate,what thickness is the stainless on manifold,have ever made one with inconel,tom

 

[stuvy]

top work there mate really like your work

 

[Mogzieno1]

Now that is some lovely fabrication, nice work!

Is that Solidworks or ProEngineer you're using for the CFD?

 

[Rick]

some lovely workmanship there mate,what thickness is the stainless on manifold,have ever made one with inconel,tom

Yes if its a race car we'll use inconel. Normally stick to thick wall stainless for road going cars though.

Now that is some lovely fabrication, nice work!

Is that Solidworks or ProEngineer you're using for the CFD?

Solidworks or Catia.

 

[Rick]

A few pictures of recent stuff.

New top on the toolbox.

A D series Vitara build with Evo turbo

Couple of Evo manifolds that are actually for Evo's.

A Golf with 1.8 20v