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Author Topic: Golf 16v Custom inlet plenum.  (Read 2174 times)

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Offline Smudge

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Golf 16v Custom inlet plenum.
« on: September 10, 2013, 08:15:04 pm »
Hello all, I thought you may be interested to see my recent work on my inlet manifold, it has now been fully tested on track and with Jason on the rollers and has proved on my mild engine setup to be quite effective after it replaced the home brew ITB setup.

See my MK2 Golf 16v in the members section.

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Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #1 on: September 10, 2013, 08:16:56 pm »
I set about buying some parts to use. The inlet track on the manifold needs a curve so that the plenum fits under the bonnet, the KR 42mm inlet is perfect for this job, it has the correct bore runners and the curve is perfect. In the vice, I cut it down with a hacksaw.





For the flange that bolts onto the head I used the lower section of the same manifold and cut it down, then milled it flat.



I also reclaimed the flange of the other end and will be using this too. Here are the basic components ready for fabrication.

See my MK2 Golf 16v in the members section.


Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #2 on: September 15, 2013, 12:44:03 pm »
To mate the runners to the head flange requires the ends of the runners to be oval. I achieved this by squashing them in a vice.





I chamfered of the edges so that I got better penetration when welding and tacked into place.





After tacking into place I test fitted onto the car.






See my MK2 Golf 16v in the members section.


Offline Robin_16v

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Re: Golf 16v Custom inlet plenum.
« Reply #3 on: September 16, 2013, 08:32:30 pm »
Nice work!

Offline JMR

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Re: Golf 16v Custom inlet plenum.
« Reply #4 on: September 19, 2013, 10:19:06 pm »
Keep em coming Tom... ;)

Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #5 on: September 21, 2013, 09:37:30 am »
After tacking in place you can see the step here that needs blending out, it's only small and to the sides only. At the point where the runners join they slightly squash in (to avoid spark plugs in OEM application) so I also built this up with weld.



To keep the wall thickness the same at the blend point I welded on extra material.



And then ground it all back.

See my MK2 Golf 16v in the members section.


Offline Tonyb

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Re: Golf 16v Custom inlet plenum.
« Reply #6 on: September 23, 2013, 06:20:10 pm »
Nice use of std parts Tom. Be interesting to see how it flows when it's done. What are you bolting on to them? be nice to use 8 injectors with the bottom injector holes still in the head end.

I looked at using an 8v OEM manifold once for injection but that is a tricky beast, especially if you havn't got the kit to weld aluminium.

Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #7 on: September 24, 2013, 05:25:38 pm »
Hi Tony
It's actually finished and has been on the car for a while now, it would be great to measure the flow and I might have to post it down to JMR over the winter months to find out. The aim when building it was to keep the peak flow as close to my ITBs as possible, but I'm sure having a plenum will be a factor.
See my MK2 Golf 16v in the members section.


Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #8 on: September 24, 2013, 06:08:11 pm »
To finish off the inlet track I bought some spun ram pipes and welded them to the flange, I had to keep the back plate in place as I did this, it was tricky to say he least!






Once tacked into place it was again tested on the car for fitment before welding fully.











Where the ram pipes join the flange some blending is required. There is plenty of meet on the flange to allow this.

See my MK2 Golf 16v in the members section.


Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #9 on: September 24, 2013, 06:13:51 pm »
Confident the inlet would fit after testing I set about fabricating the plenum chamber.














See my MK2 Golf 16v in the members section.


Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #10 on: September 24, 2013, 06:17:47 pm »
After a bit of measuring up I started to cut the and weld the sides.
















See my MK2 Golf 16v in the members section.


Offline Tim Moll

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Re: Golf 16v Custom inlet plenum.
« Reply #11 on: September 24, 2013, 06:24:59 pm »
Great fabrication there Tom...I know who to come to if I need any ally fab work done  ;)

Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #12 on: September 30, 2013, 06:55:35 pm »
Thanks Tim.
See my MK2 Golf 16v in the members section.


Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #13 on: September 30, 2013, 07:06:24 pm »
I welded the joints on the inside as well and then ground them away to give the smoothest finish I could acheive. Here you can see the process in action, roughly sanded with a finger sander - best bit of kit in the world when welding and cleaning things up etc.






The front part was the most complex, I made a card template first, the cut the sheet Ali, then annealed it and then rolled it to shape.



The end dome was made up of many pieces, the weld was built up on the inside and then ground away to give a smooth transitional finish, the outside is still squared, here I blasted over the welds to reduce them in hight so that it was to ground off, looks messy but was worth it.







You can see the weld being built up and blasted smooth.

See my MK2 Golf 16v in the members section.


Offline Smudge

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Re: Golf 16v Custom inlet plenum.
« Reply #14 on: October 10, 2013, 06:36:19 pm »
I blended the joint between the bell mouths and the flange then hand sanded throught to grade 1200. 



The full inlet track getting there.





The end dome roughly sanded ready to be joined.

See my MK2 Golf 16v in the members section.


 

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