Oh yeah baby!!! :D

A little after you started producing the TBs again I wondered if we wouldbe lucky enough to get a manifold up and running again.

You can put me down for 1! If I could use 2, I would :D

Good news!

And great timing too!!!!

Let me know how much you want and Ill pay you a deposit and drop cash off when I have spare so I can get one of these babies.

Fantastic to hear.

Got my thumb on the trigger to make a deposit when you're ready:)

Fantastic to hear.

Got my thumb on the trigger to make a deposit when you're ready:)
:stoopid: :stoopid: :stoopid:

Great to hear Ian, hopefully the price will be competative with the "other" manifold supplier to the magna owners. :)

I told you I'd come thru for you!! 350hp should be a cake-walk for your rebuild now! lol

It'll probably take somewhere near a month to get a proto churned out and evaluated. Any mould changes necessary will obviously be covered too.

In negotiations with a polisher too for those who like to wear sunnys when under the hood :cool:

Oh yeah baby!!! :D

A little after you started producing the TBs again I wondered if we wouldbe lucky enough to get a manifold up and running again.

You can put me down for 1! If I could use 2, I would :D

In my head I'd already put YOUR name on one. An no, I'm not doing anything or plan to with a supercharger kit. Best left to the likes of Raptor etc, people better financed and versed in these things. This is just a hobby (expensive one :cool: ) for me to keep my mind active.

And if we knock 2sec of our 400m time than that's good too!

I told you I'd come thru for you!! 350hp should be a cake-walk for your rebuild now! lol

It'll probably take somewhere near a month to get a proto churned out and evaluated. Any mould changes necessary will obviously be covered too.

In negotiations with a polisher too for those who like to wear sunnys when under the hood :cool:

Heheheh me like.

Engine is coming along slowly but surely, im not really in a rush to finish it as i got too many other things on the go at the moment that are of more importance than a silly old magna :)

You have my number if ya want to contact me when ya need any ideas or info :D

Aren't you sick of me pumping you for info yet ;)

For the PMer's:

1) There will be plenty of these to go around.
2) Yes the stock ecu has plenty of ceiling to accommodate this mod without a piggyback or replacement ecu. I have run the prototype on my TJ2 and my old TF - both with spectacular results.
3) I will provide necessary options such as extrude honed runners, polishing etc if the demand is there.

I'm also open to suggestions on other features people would like to see on the manifold. Please post them here rather than pm'ing me - space is in short supply in my mailbox of late.

:dancin: u ripper!!! cant wait for this!!:D

In my head I'd already put YOUR name on one. An no, I'm not doing anything or plan to with a supercharger kit. Best left to the likes of Raptor etc, people better financed and versed in these things. This is just a hobby (expensive one :cool: ) for me to keep my mind active.

And if we knock 2sec of our 400m time than that's good too!

Your a champ! Got my name down already!

Just let me know when you need a deposit or payment.

I was hoping for the manifolds but didn't expect the super charger kit to come through, had to ask though :)

Here's a sneak preview of the internals for the runners. I am probably committing commercial suicide but I really want to share the progress with everyone.

Of course this is mild steel and not anywhere near finished quality. Production items will be 100% 316 stainless steel, polished is a posibility at extra cost but I'll worry about that down the line if this one works as expected.

Enjoy.

I've probably just saved half of AMC a few hours surfing porn lol

I think the concept is very much similar with that of Weapon R intake system, good to hear that you applied it to the intake manifold.
Article here: http://www.prostreetonline.com/weapon_r_secret_weapon_intakes.html

I think the concept is very much similar with that of Weapon R intake system, good to hear that you applied it to the intake manifold.
Article here: http://www.prostreetonline.com/weapon_r_secret_weapon_intakes.html
While I'm not familiar with this product, it is a working example of a prototype I started last year - still sitting on the bench :cry:. I have bolted it on briefly and it absolutely roared, but it had a pin hole in a weld that needs attention.

Either way, I believe this approach works and works well, I also KNOW that the twin runner system works very well too and it is the TWIN RUNNER system that I am putting into peoduction.

It is paramount for people reading the weapon-r info to understand that their product is only a replacement from the air filter to the throttle body - my replacement manifolds are from the throttle body to the engine. A weapon-r style CAI as well as the replacement manifolds would be a fearsome combination.

Maybe I should knock some of these styled cai pipes up heh?

While I'm not familiar with this product, it is a working example of a prototype I started last year - still sitting on the bench :cry:. I have bolted it on briefly and it absolutely roared, but it had a pin hole in a weld that needs attention.

Either way, I believe this approach works and works well, I also KNOW that the twin runner system works very well too and it is the TWIN RUNNER system that I am putting into peoduction.

It is paramount for people reading the weapon-r info to understand that their product is only a replacement from the air filter to the throttle body - my replacement manifolds are from the throttle body to the engine. A weapon-r style CAI as well as the replacement manifolds would be a fearsome combination.

Maybe I should knock some of these styled cai pipes up heh?

Yeah, I love to see that...you're a winner:D

if you could have the allowance for the clip that bolts onto the manifold to take the engine cover would be great too....bring this on!!

I think the concept is very much similar with that of Weapon R intake system, good to hear that you applied it to the intake manifold.
Article here: http://www.prostreetonline.com/weapon_r_secret_weapon_intakes.html

Nice find!!! Know if you can get them in Aus??

Nice find!!! Know if you can get them in Aus??

nah, maybe EZ can do one for you.:D
edited: try this online shop http://www.justjdm.com.au/cart/agora.cgi

hmm might be interested :) suit an auto alright? and i dont have a CAI yet, so yes knock up some of those CAIs ;)

hey EZ,

that CAI if u managed to design something like that id take it for sure.

as far an the inlet manifold goes im a bit half and half, as i have the rpw plenum so id be keen to know the sort of gains ur manifold would have over the rpw plenum.

i would like to assume urs will make better power at certain rev ranges as u have revised the runner lenghts and have an extra 6 to improve velocity! but i know ur not the type of person to openly knock another product, im not asking if it will be better as the info u have provided proves it will lol, im more interested in how much better :P

oh and once again i def VOTE1 ez boy intake piping FTW, then u wouyld have designed a whole intake systme for a magna... POD BOX, INTAKE PIPING, FLOWED TB's and INLET MANIFOLD... Woa!

So is it safe to assume that this project is underway again?

was just about to post up in your TB thread wether you were gonna start this project agian and it occured to me to do a search and vola i would def be in for all you mods so far TB, mani and cai (pending you run with the idea) if you do you should consider doin up kits at a discount price ie all you mods in one package well just some food for thought and definatly glad your back on the scene


toocky

Like anything it's not safe to assume much. Do however assume that I have been exploring manufacturing processes for several months, and also assume that I want this project to proceed and quickly.

I am looking forward to dyno curve comparisons over stock manifold to see where in the rpm (besides everywhere!!) the most benefits are seen. Peak power will certainly be up because the prototype pulled higher rpm than the oem. It was pullling hard still at 7000rpm before the auto started hunting for the next ratio. Peak power is calculated from rpm x torque, so I'm less than interested in kw printouts; I want to know how hard the motor is turning the driveshaft and maintaining that twisting force for as long as posible thru as much of the rpm band as posible. Then you will truely have a quick car.

To this end I will be seeking a 3.5 manual preferably, must have extractors and exhaust done, cai and other breathing mods would be great, to be a test car on the dyno. I am certain that I can offer a VERY ATTRACTIVE renumeration package for your time. I.e. you will likely get to drive home with the replacement manifold still on your car and a big fat grin!

If this is you and you're in Newcastle, Central Coast or even Sydney I'd love to hear from you!!

and does that mean the standard manifold in the boot.

im interested in helping out, but dont really have any exhaust mods other than a rear muffler.

and everthing else is stock manual ralliart

and does that mean the standard manifold in the boot.

im interested in helping out, but dont really have any exhaust mods other than a rear muffler.

and everthing else is stock manual ralliart

Yep, stock item in the boot. A Ralliart unfortunately is a bit high spec for the test, hoping for a non internally worked vehicle. I think the above mod list would be indicative of where most 3rd Gen modders are upto or in progress. Sort of waiting for a set of cams or a Raptor SC kit to magically appear under the xmas tree....:D

ian, did you get divorced or does the mrs understand you need a hobby?

To this end I will be seeking a 3.5 manual preferably, must have extractors and exhaust done, cai and other breathing mods would be great, to be a test car on the dyno. I am certain that I can offer a VERY ATTRACTIVE renumeration package for your time. I.e. you will likely get to drive home with the replacement manifold still on your car and a big fat grin!

If this is you and you're in Newcastle, Central Coast or even Sydney I'd love to hear from you!!

Gee, I wish I fulfilled the criteria. Have all the other bits apart from the manual.

Like anything it's not safe to assume much. Do however assume that I have been exploring manufacturing processes for several months, and also assume that I want this project to proceed and quickly.

I am looking forward to dyno curve comparisons over stock manifold to see where in the rpm (besides everywhere!!) the most benefits are seen. Peak power will certainly be up because the prototype pulled higher rpm than the oem. It was pullling hard still at 7000rpm before the auto started hunting for the next ratio. Peak power is calculated from rpm x torque, so I'm less than interested in kw printouts; I want to know how hard the motor is turning the driveshaft and maintaining that twisting force for as long as posible thru as much of the rpm band as posible. Then you will truely have a quick car.

To this end I will be seeking a 3.5 manual preferably, must have extractors and exhaust done, cai and other breathing mods would be great, to be a test car on the dyno. I am certain that I can offer a VERY ATTRACTIVE renumeration package for your time. I.e. you will likely get to drive home with the replacement manifold still on your car and a big fat grin!

If this is you and you're in Newcastle, Central Coast or even Sydney I'd love to hear from you!!

Pity i didnt live closer Ian as id offer you my car as a test mule. :) But i guess my new engine would be abit too worked to fit the normal extractor, exhaust and CAI mods.

If u are interested i have a completely stock manual TL VR with just a Magnaflow muffler on it. Be good for stock comparison. I would be more then happy to pay for the dyno runs, as i live in adelaide and will pay up for freight if u so wish.

Im happy to offer my car for dynoing etc, only live 5 mins away, got the headers, cat and exhaust that your dad done for me :) got NZ CAI and K&N panel.......only downside is its an auto, but more than happy to help if you need it.

let us know when man. I have a stock manual with a TH smoker cai. Also have extractors and hiflow cat waiting to be put on. Might make a road trip up! how far is newcastle from melb? hhahah

haha.. scrap that! i just relised where newcastle is! but good luck! i'll be Extremely interested when you have the ready for sale!

Incase you don't find the perfect candidate, I'm more than willing.

I'm driving a manual 3.5L TJ sports, only relevant engine mods are magnaflow muffler and DIY CAI however, no extractors/hi-flow cat.

However, I can get pacies put in, but that depends on your renumeration package, as I won't have enough cash left to buy the manifold @ full price for a little while.

I live in Sydney, but i'm quite happy to drive down to Newcastle, and I'm very flexible time wise (only 3 days uni atm, can come on short notice). Send me a PM if you're interested :)

this still going?

and when can i have one :D

3.5 Manual + Cruise + Ralliart goodness

']this still going?

and when can i have one :D

3.5 Manual + Cruise + Ralliart goodness

According to EZboy he'll have a prototype ready to do a final test on in 6-8 weeks..so not long after that I imagine.

INLET MANIFOLD UPDATE

I am expecting some firm pricing from the foundary in the next 2wks. Then a prototype will be made, dyno'd etc and manufacturing will commence if all goes to plan.

The manifold will be a graduation from the twin runner design. Made from cast aluminium and machined to accept the standard bolts, vac lines, tb, tb cable. Aiming to accept the stock engine cover and clear strut braces.

I am trying to establish options for the manifold such as polishing and heat protective coating. I think HPC would be a wise idea given it's proximity to the rear exhaust header.

I wont know anymore until I know any more :confused:

Please post here, save my PM inbox the stress until production commences. Thanks :cool:

INLET MANIFOLD UPDATE

I am expecting some firm pricing from the foundary in the next 2wks. Then a prototype will be made, dyno'd etc and manufacturing will commence if all goes to plan.

The manifold will be a graduation from the twin runner design. Made from cast aluminium and machined to accept the standard bolts, vac lines, tb, tb cable. Aiming to accept the stock engine cover and clear strut braces.

I am trying to establish options for the manifold such as polishing and heat protective coating. I think HPC would be a wise idea given it's proximity to the rear exhaust header.

I wont know anymore until I know any more :confused:

Please post here, save my PM inbox the stress until production commences. Thanks :cool:

Bring it on Ian.

Will call you soon, regarding ceramic coating. Picked up my lower manifold today all cermaic coated and was discussing your inlet plenums with the guy and hes keen to do ya a possible good price on coating them for you.

INLET MANIFOLD UPDATE

I am expecting some firm pricing from the foundary in the next 2wks. Then a prototype will be made, dyno'd etc and manufacturing will commence if all goes to plan.

The manifold will be a graduation from the twin runner design. Made from cast aluminium and machined to accept the standard bolts, vac lines, tb, tb cable. Aiming to accept the stock engine cover and clear strut braces.

I am trying to establish options for the manifold such as polishing and heat protective coating. I think HPC would be a wise idea given it's proximity to the rear exhaust header.

I wont know anymore until I know any more :confused:

Please post here, save my PM inbox the stress until production commences. Thanks :cool:

when you are talking vac lines do you mean all of them including being able to use traction control as well:pray:
edit. realised the bits i was talking about are on the t/b

Hi, Just wondering when you think that this project will be ready for production cause I am replacing the engine in my TE with a new long motor and wanting better performance out of the stock motor. I was looking at the RPW manifolds but have since been advised otherwise.

According to EZboy he'll have a prototype ready to do a final test on in 6-8 weeks..so not long after that I imagine. :slap:

Um...ignore what I said..what manifold? :P

Um...ignore what I said..what manifold? :P
what did I miss?

you drinking again bernard?

']what did I miss?

you drinking again bernard?

Apparently I'm not supposed to say these things..so nothing to see hear :p

And yes, I may have had a few pre-breakfast drinks lol

EZBOY, I've got a manual tj VRX with rpw race extractors and cai. Exhaust is standard VRX
Live in Newcastle area.!!









Like anything it's not safe to assume much. Do however assume that I have been exploring manufacturing processes for several months, and also assume that I want this project to proceed and quickly.

I am looking forward to dyno curve comparisons over stock manifold to see where in the rpm (besides everywhere!!) the most benefits are seen. Peak power will certainly be up because the prototype pulled higher rpm than the oem. It was pullling hard still at 7000rpm before the auto started hunting for the next ratio. Peak power is calculated from rpm x torque, so I'm less than interested in kw printouts; I want to know how hard the motor is turning the driveshaft and maintaining that twisting force for as long as posible thru as much of the rpm band as posible. Then you will truely have a quick car.

To this end I will be seeking a 3.5 manual preferably, must have extractors and exhaust done, cai and other breathing mods would be great, to be a test car on the dyno. I am certain that I can offer a VERY ATTRACTIVE renumeration package for your time. I.e. you will likely get to drive home with the replacement manifold still on your car and a big fat grin!

If this is you and you're in Newcastle, Central Coast or even Sydney I'd love to hear from you!!

EZBOY, I've got a manual tj VRX with rpw race extractors and cai. Exhaust is standard VRX
Live in Newcastle area.!!

Shhh go away :gtfo:

:P

Shhh go away :gtfo:

:P

lol I was wondering when this was going to heat up. Newcastle-ish would save me a lot of fuel....

lol I was wondering when this was going to heat up. Newcastle-ish would save me a lot of fuel....

Well I did say I was quite happy to drive to Newcastle :)

hurry up n drive there!!!!:P

haha.. i want one!

Well I did say I was quite happy to drive to Newcastle :)

I know I know. As previously indicated to you, you have 1st option to be the dyno car - but if all else fails it's great to have several standby vehicles. So again, big thanks to the people who've put up their hands (and cars).

Trying to get a meeting with the foundry and mold maker this thursday to get the mold started and hopefully pour some manifolds later next week. :dancin:

Haaaaa, Ian, you're back. Good to hear.
As usual, I'll be waiting here very impatiently for the results and next phase of the project. Wishing u all the best.
BTW, remember I told u about my mate and me talking about starting this stuff - got held by my holiday and was about to get back to it. So I think I wait a bit more now....:)

Haaaaa, Ian, you're back. Good to hear.
As usual, I'll be waiting here very impatiently for the results and next phase of the project.

Bah ... typical ;)

Bah ... typical ;)

Typical? As in, me being impatient....??? Nah NEVER!!! :badgrin:

hey ez, this sounds cool as!
how many manifolds are you expecting to pour coz ill be down gosford about 19th may and i could come get one if they ready by then...

im putting my "new" engine in on th 13th :D

of course my intrest will be directly relative to the power figures...but a promise of better fuel economy could get me equally intrigued

** UPDATE **

I met with the mould maker today. He's stressed about the design but assures me it will work - but will take him about 4wks to complete it along with other projects he already has booked in.

So, in short I've just approved the comstruction of the mould, costing between $1500-1800. Hopefully this will be recouped and I wont get divorced by this project :redface:

** UPDATE **

I met with the mould maker today. He's stressed about the design but assures me it will work - but will take him about 4wks to complete it along with other projects he already has booked in.

So, in short I've just approved the comstruction of the mould, costing between $1500-1800. Hopefully this will be recouped and I wont get divorced by this project :redface:

you'd be getting the 48% rebate back for this piece of research would you not be??

Also i wanted to ask what type of casting are you using, i assume sand. Just out of interest as i reckon this would be a bitch to make

lol i made a qut paperweight through this process, i am l33t. It's pretty ****

Hey! I've just discovered AMC and all these sweet as things i can do with my magna, i got one thing to say... SWEET AS!!

So! I'm just jumping on to this band wagon! :D

3rd Gen 3.5L V6 Manual

Hopefully this will be recouped and I wont get divorced by this project :redface:

Not to worry - my dog (small 40 kg German Shep) promised to share his house with u if things get bad.
I hope we get more than 3 monetary deposits this time towards this case! :cool:

You could always stay in my spare room if things came to the worst... At the cost of a manifold :P

hey ez any word from the mold maker gettin closer to 4 weeks well hope this project continues

n00b question comin up fellas:

Whats EGR?

My head is absolutely cooked atm.

n00b question comin up fellas:

Whats EGR?

My head is absolutely cooked atm.
Exhaust Gas Recirculation

Exhaust Gas Recirculation


Cheers for that, i knew it something to do with exhaust haha.

So whats the downfall of this not being supported if you had ones of these manifolds.

Oh and would barry's manifold gasket still work with this?

Cheers for that, i knew it something to do with exhaust haha.

So whats the downfall of this not being supported if you had ones of these manifolds.

Oh and would barry's manifold gasket still work with this?


Hi Oxford
A small amount of Exhaust Gas is Recirculated into the inlet to reduce combustion temp and therefore some of the tailpipe pollutants

If you are replacing the extractors and the vehicle had EGR when manufactured, then the new system must also have EGR to remain street legal

The EGR is controlled by a sliding valve bolted to the rear of the manifold that permits more, or less exhaust gas into the inlet manifold

The problem is that the exhaust gas is quite sooty, and it mixes with excessively oily blow-by fumes from the crankcase to form a sludge

This sludge eventually clogs the EGR valve and it tends to stick open, letting in this power-robbing dilution to affect the smooth running of the engine ( it's basically only supposed to operate when in light cruise)

This problem is typical of when you have to put your ride in for an expensive service because of rough idle and running problems

To help solve this, I have come up with a solution

To reduce the sootiness of the exhaust, raise the temp of the fuel by a prescribed amount using the Fuel Rail kit

The fuel vaporizes more easily and there is noticeably less soot at the tailpipe

To reduce the oil mixing with the intake air-fuel charge, fit a simple filter or catch can (as already described here in AMC) from the PCV to the vacuum line

The PCValve can also stick partially open, so I have trialed a catch can where the valve is isolated from it’s normal place on the front valve cover, and sits on the top of the catch can in a vertical position

This way the valve closes more positively under gravity and cannot stick open

The standard inlet manifold gasket also has poor inlet runner isolation and allows oil to cross-contaminate the intake runner air

You can use my new manifold Gasket Kit which seals properly (and directly replaces the standard gasket) to solve that problem, and yes it will work with the new manifold

Cheers, Barry

Cheers for that barry. Explains a lot. Very interested in this now! Watching this space intently!

Oh i think i owe you a pm aswell.

hell yes
def interested but up to funds available
2000 TJ sports FWD

cant wait for more info.

Hi Oxford
A small amount of Exhaust Gas is Recirculated into the inlet to reduce combustion temp and therefore some of the tailpipe pollutants

If you are replacing the extractors and the vehicle had EGR when manufactured, then the new system must also have EGR to remain street legal

The EGR is controlled by a sliding valve bolted to the rear of the manifold that permits more, or less exhaust gas into the inlet manifold

The problem is that the exhaust gas is quite sooty, and it mixes with excessively oily blow-by fumes from the crankcase to form a sludge

This sludge eventually clogs the EGR valve and it tends to stick open, letting in this power-robbing dilution to affect the smooth running of the engine ( it's basically only supposed to operate when in light cruise)

This problem is typical of when you have to put your ride in for an expensive service because of rough idle and running problems

To help solve this, I have come up with a solution

To reduce the sootiness of the exhaust, raise the temp of the fuel by a prescribed amount using the Fuel Rail kit

The fuel vaporizes more easily and there is noticeably less soot at the tailpipe

To reduce the oil mixing with the intake air-fuel charge, fit a simple filter or catch can (as already described here in AMC) from the PCV to the vacuum line

The PCValve can also stick partially open, so I have trialed a catch can where the valve is isolated from it’s normal place on the front valve cover, and sits on the top of the catch can in a vertical position

This way the valve closes more positively under gravity and cannot stick open

The standard inlet manifold gasket also has poor inlet runner isolation and allows oil to cross-contaminate the intake runner air

You can use my new manifold Gasket Kit which seals properly (and directly replaces the standard gasket) to solve that problem, and yes it will work with the new manifold

Cheers, Barry

Hey Barry As with everyone else i've been watching the tread closely (can't wait to start lining EZ Boy's pockets with cash) just a side ques' how legal is it to have a little filter or catch can fitted to a 3rd Gen.:confused:


And how far along is your catch can project.:D

Hey Barry As with everyone else i've been watching the tread closely (can't wait to start lining EZ Boy's pockets with cash) just a side ques' how legal is it to have a little filter or catch can fitted to a 3rd Gen.:confused:


And how far along is your catch can project.:D

You can legally run a catch can, but it must not be vented. In other words you can't use those little air filters, it must be a sealed catch can.

** UPDATE **

The mold maker is inundated with work, and unfortunately this project takes the backburner. I just have to accept that otherwise he wouldn't have been able to take it on at all. To compound matters he's just injured his back (monday) and is taking time off on doc's orders.

Rescheduling for July - if I can swing late june then it's a bonus. Can't do much about it :rant:

Cheers for the update EZ, still very interested in this. However the set back is actually better for me, and i think everyone coz tax back is just around the corner!

Cheers for the update EZ, still very interested in this. However the set back is actually better for me, and i think everyone coz tax back is just around the corner!

I was going to say that. Lots of young blokes with Magna's will suddenly have more cash to spend around July. Best time to get it off the ground!

:bowrofl:

Cheers for the update EZ, still very interested in this. However the set back is actually better for me, and i think everyone coz tax back is just around the corner!

:stoopid:

It is done.

The mold is drying waiting for it's last coat of paint and then it's off to the foundry.

Enjoy the sneak peaks:

Now that is a work of art! Seriously! :bowrofl:

Good stuff!!!

Ive got a moneybox that Ive been putting my change into just incase this project got off the ground, looks like my savings may pay off :)

That is ****in sweet man, well done.

Should've got the EZ imprinted on the top side though!

:D

That looks sweet!! Beautiful job!!
And even better it looks stock so no one (read insurance :P ) other than a mitsi mechanic will ever tell!

yeah that looks mad as!

so i'm guessing the stock engine covers will fit back on?

Looks awesome, love the "EZ" embossed on it :D

Sorry if it's already been answered, but what are the performance figure gains from this mod?

im loving what your doing with it now that you've got that done what else is there that needs to be done and approximately how long will it take b4 you get the first batch

i pretty sure it will but just asking anyway this will fit both 3L and 3.5L right?

Sorry if it's already been answered, but what are the performance figure gains from this mod?

Unknown as of yet, waiting for one to be made, then it will be put on a donor car then dyno'd.

Unknown as of yet, waiting for one to be made, then it will be put on a donor car then dyno'd.
Before and after dynos - same day, same dyno hopefully.

Looks very cute. :D
I'm looking at the plenum chamber - how much larger in capacity is it compared to std chamber? As you know, there is a quide line of 2.5 times the engine capacity for the whole intake system, including actual intake manifold. 3L std system volume is ruffly 5.7 L and it should be increased to ruffly 7.5 L for good results.
Have u decided on final cost as yet?

The plenum volume is larger by approx 1/3, with consideration given to resonance tuning, bellmouthing, runner volume and flow intersection. It will work. It'd better work!!:bowrofl:

The "EZ" is deliberately placed underneath next to the serial number so that it maintains the stock look. But I understand that it would be cool to have some big, tough, catch phrase on the top. I couldn't think of one ;) The other advantage as previouslt stated, is the item will look near stock and will keep the authorities etc off your back. Esp if you've got P's and you've just emerged from a cloud of fried tyre smoke :naughty:

I have been blessed by an AMC member who has stepped up to finance the mold which allows me to get it to the foundry for first trial castings asap. Otherwise this would all have to wait until July-August.

There is considerable work involved in making each sand mold up so the number of EZ Plenums that can be quickly made is limited by the number of hours in the day....

Once a satisfactory pour is done, the EZ Plenum will be cleaned up, end capped, holes drilled and tapped where necessary and bolted onto my AWD for some evaluation. If it's all good news I have a car ready to perform a before and after dyno. The dyno runs will be performed by a 3.5L manual with extractors and catback 2.5" system. Pretty standard mods for most cars in the club. The runs will be performed within an hour of each other. The motor temps should be similar, no fiddling with tyre pressures etc either. I'm not really interested in *peak* hp or kw gains, I want to see improved torque accross the whole rpm band. If peak power is up then that's good too.

My gut feeling?? I am expecting strong mid rpm gains 3000-5500ish with improved top end pull upto 7000. Hp gains? They will be there, as far as peak gains I think there will be a nice surprise.

Very interesting and just to re-confirm, how much are you estimating the final cost to be again? (I have to start saving:D )

Just found something a little interesting.

Have a look at this.

http://www.ffdynamics.com/stealth3000gt.html

Its for a 3000Gt so obviously for a turbo but same 6g motor. It says you can use it for N/A also.

Look at the design and how they comment on getting the right airflow to the 6th cylinder.

Is your design anything like this EZ?

EZ did you get someone for your dyno test yet.

I have a AWD with your pod box extractors and custom exhuast thats willing to try it Its tiptronic is the only catch

EZ did you get someone for your dyno test yet.

I have a AWD with your pod box extractors and custom exhuast thats willing to try it Its tiptronic is the only catch

Thanks for the offer. I do have a 3.5L manual with extractors, 2.5" system etc., all tee'd up for the dyno runs.

will3690: That manifold doesn't really work well with my ethos of keeping a stock look and changing critical areas of the manifold notably runner design. That style manifold would imo suit high rpm mostly. Larger plenum volume and improved runner distribution are all useful features - I just think there are more visually appealing ways to achieve it ;)

Final Cost?? Expecting a price in the $900 region. Will know once machining cost are known etc and gains made. If it makes 50hpatw then I'll put the price up :D

What if it makes 50hpatw then I'll put the price up :D

What if it makes 49 :D

Just found something a little interesting.

Have a look at this.

http://www.ffdynamics.com/stealth3000gt.html

Its for a 3000Gt so obviously for a turbo but same 6g motor. It says you can use it for N/A also.

Look at the design and how they comment on getting the right airflow to the 6th cylinder.

Is your design anything like this EZ?

That looks like Cletus and Jimbob welded it together in their backyard in Alabama.

"Beutiful brass fittings" :bowrofl:

yeah... never been a big fan of american's offerings for the ricer/tuner market.... EZ Boy's looks much more professional, and much less chance of crappy welds leaking crap into your intake!

yeah.. much less chance of crappy welds leaking crap into your intake!


did you guys look at the welds. there about as perfect as you can get:nuts: like a roll of coins. sure it's not as pretty as ez boy's but isn't his one molded peice instead of a few weld bits together. I think it looks good no need to cover nice welds like that just for cosmetic's sake or for that smooth look. It shows that they do have some fabrication talent and don't mind showing it. have a look at a drag cars space frame. all the welds are like that (for strenght not looks) they don't cover them cos 1. wasted time 2.they like to show how good they can weld. those welds above are very good , if you've done any welding you'll know that.

anyway back on topic. your design does look incredible ez (wasn't putting it down ^) and good luck with the sales.

did you guys look at the welds.

nah didn't actually! just the engine bay pic... the welds looks pretty damn good, i'd just much prefer the stock look EZ Boy is going for instead of the massive intake slab

nah didn't actually! just the engine bay pic... the welds looks pretty damn good, i'd just much prefer the stock look EZ Boy is going for instead of the massive intake slab

ez has done a top job. if u bought a magna with it on im sure ud never know it wasn't factory. it does look extremly well made and well finished. i definetly tip my hat to him.

I have dabbled into TIG welding and it is a very time consuming process. The welds present on that manifold certainly at a glance appear to be of very high quality. Pity it looks so raw.

UPDATE: I have paid for and collected the mold in it's entirety and will be in touch with the foundry on monday to get it out to them :dancin:

EZ Boy is this still on track for a late June/sometime July release?

Once they are initially released, how long do you think you'll continue production for? ie are you only doing a single "production run" or are you going to make them as needed for a couple of months?

Reason I ask is that I'm about to get my car lowered at the end of the month... but conviently enough, your intake manifold is the same price as getting my car dumped :P

EZ Boy is this still on track for a late June/sometime July release?

Once they are initially released, how long do you think you'll continue production for? ie are you only doing a single "production run" or are you going to make them as needed for a couple of months?

Reason I ask is that I'm about to get my car lowered at the end of the month... but conviently enough, your intake manifold is the same price as getting my car dumped :P
I would say make your car handle better first. Then add more power :)

I can get my car lowered at any stage though (although the sooner the better :P). I wouldn't want to miss out on something like this.

EZ Boy is this still on track for a late June/sometime July release?

Once they are initially released, how long do you think you'll continue production for? ie are you only doing a single "production run" or are you going to make them as needed for a couple of months?

Reason I ask is that I'm about to get my car lowered at the end of the month... but conviently enough, your intake manifold is the same price as getting my car dumped :P

Aiming for late June/early July release. Depends on the current workload at the foundry - everyone trying to rush jobs thru pre-EFY.

I will always have the mold (pending offers :D ) so production will be mini-runs on demand hopefully. The more I can do at a given time, the more worthwhile for the foundry too. Got to keep the foundry happy!!

Dump your ride, then start scratching $ together as the manifold output figures and items become available. Or not, and just grab the manifold. :cool:

Aiming for late June/early July release. Depends on the current workload at the foundry - everyone trying to rush jobs thru pre-EFY.

Sweet, count me in, KL AWD. I'm sure there's a fair line.

Tj Sports 2000 - Manual. Im keen to see the results!

have been watching this with interest for quite some time.. looks as though my tax should be able to cover this..

KE 3.5 Auto Wagon

Several people have pm'd re the flood in Maitland and surrounding areas, and YES the foundry has been effected. I am still waiting on an update from them to gauge the damage, if any, and likely resumption of production etc.

** UPDATE **

There has been some excitement trying to get the mold and sand to separate :rant: Alternative methods are being looked into along with changes to the mold to aid core removal. Will update as news breaks.

Thanks. :cool:

Turns out the problem was with the sand not holding the runner shape well.

I've switched foundaries and am employing a different sand mix which has tested very well over the weekend. The cores have maintained complete shape and were finalised this afternoon.

Wednesday 18th is THE day of the pouring! :dancin:

If they bump it back again I'm going postal!!

If they bump it back again I'm going postal!!


Which way will you be heading so i can stay out of your way?

Back to topic, how rough will the inside finish be?

Inside finish,
Make sure that the foundry dips or paints the cores that form the inner surfaces of the casting.
The "paint" fills in the small gaps between the sand grains and achieves a much smoother surface.
The difference between a painted and unpainted core is very noticeable.
Gerry.

hmmm I was going to put my tax return into my savings account after I emptied it for my new audio system... but I don't know now... :P

yeah, 3L

Wednesday 18th is THE day of the pouring! :dancin:

It's now Fri 20.7. at 15.21 hrs....!!!!!
What? Whaddaya mean impatient???? :rant:

It's now Fri 20.7. at 15.21 hrs....!!!!!
What? Whaddaya mean impatient???? :rant:

My 1-off isn't as important as a $20000 overseas shipment :doubt:

The VERY FIRST manifold poured sucessfully on friday morning and is waiting to have the cores removed and tidied up. When I get my hands on it (mon night or tue morn) I will be photographing it like it was Elle McPherson having a shower at my place! :D

Great progress.
I am sure that many of the 3.5l owners want to hear how this is all working out!!

Gerry

Great progress.
I am sure that many of the 3.5l owners want to hear how this is all working out!!

Gerry


not just the 3.5 owners mate. This will fit a 3.0L also.

When I get my hands on it (mon night or tue morn) I will be photographing it like it was Elle McPherson having a shower at my place! :D

you no im not sure which i would prefer is it posible to have both Elle McPherson having a shower with the manifold that would kick ass but any who great to see this has finally gotten so far will be good to see some results finally can just imagine the kickass feeling that u will have when u strap it on

you no im not sure which i would prefer is it posible to have both Elle McPherson having a shower with the manifold that would kick ass but any who great to see this has finally gotten so far will be good to see some results finally can just imagine the kickass feeling that u will have when u strap it on
Oh.. my... god :bowrofl: Had experience there dude?

Oh.. my... god :bowrofl: Had experience there dude?

Bwahahahahahahaha! *wipes away tear*

But could you imagine the advertising for Ez Boy if he had Elle or someone like that in the shower holding for the manifold?

<Pic is here>

Manifold... for sale.
<Stats>
$XXX

(Woman not included in price)

:bowrofl: Photochop Challenge!!

:bowrofl: Photochop Challenge!!


first need a pic of manifold and for the befit of our community i will now procede to research some of elles pics :D

Okay then; here's some pics of the prototype that I took today :dancin:

Haven't done a thing to it yet, needs machining, drilling, pluging, finishing, etc but the hard part is complete. Weighs in at about 10kg!! so it's nice and strong.

Pics:

As promised retains the stock look. Aiming to mount ALL ancillaries including engine cover. Will utilise existing plenum mounting brackets at the rear of the plenum. Can accept an oversized TB upto 70mm. Internal bellmouthing. Knife-edged intersection of runners. Enlarged plenum volume to ensure full airflow at redline. Dual runners for improved torque availability, increased efficiency and hence better fuel economy.

Will keep the updates coming...

Btw, the foundary is keen to improve the product as am I. I am looking into a bead-blast finish. The foundary will be adjusting their pull timing and chemical sand mix as the weather warms up again soon.

Rarely before has ore dug from the earth been crafted into something so beautiful.

Rarely before has ore dug from the earth been crafted into something so beautiful.
there is another such exception :Dclickey:D (http://www.vassg.hu/fotok/penis.jpg)

Very impressive - I bet you can't wait get it faced and bolt it on :)

woohoo!!! We can see it at last!!!!

Looking good.
I love the design detail in the casting.
Good luck with the fun part of fixturing the casting for machining.
Keep the progress reports and photos coming.
If you want fantastic high res photos I am willing to oblige for a freebie!!



Gerry

Looking good.
I love the design detail in the casting.
Good luck with the fun part of fixturing the casting for machining.
Keep the progress reports and photos coming.
If you want fantastic high res photos I am willing to oblige for a freebie!!

Gerry

The facing has been done, bolt and screw drilling is next. Found a 1.1/2" welsch plug in the shed so that end will be finished soon. I've got the jig from the stainless manifolds I was going to make (thank God that idea fell from grace!) so the plenum support brackets will be aligned too. The throttle cable bracket is being done as we speak care of another jig that will locate the best angle and cable length from the TB.

Wanna be some bloody good photos for a freebie! ;)

Will keep everyone appraised.

What happened to the Photochopping?? lol

well i did it with fireworks so its no crash hot but u get the idea and i couldn't just do it without a good slogan so enjoy

http://img2.freeimagehosting.net/uploads/th.a6a11bff1a.jpg (http://img2.freeimagehosting.net/image.php?a6a11bff1a.jpg)

See I think the photochop slogan shoulda said something about heavy breathing....

Any news??

Gerry

read thread from start to finish. excellent outcome. my only advice would be to consider extrude honing instead of machining the raw casting. much easier and neater,and probably improve the flow of the thing. theres only so far into the runners you can go with regards to porting tools and the like. cant wait to see this project come to fruition.

read thread from start to finish. excellent outcome. my only advice would be to consider extrude honing instead of machining the raw casting. much easier and neater,and probably improve the flow of the thing. theres only so far into the runners you can go with regards to porting tools and the like. cant wait to see this project come to fruition.

Extrude honing is great for many things but the cost vs gains on the average NA magna V6 probably aren't there. Wilder motors (read: "cams") should show gains across the board. Once the setup work is done the cost per unit *should* come down. I recall the cost being in the 300-450 ballpark but that price is over a year old. It might have even been as high as 600 with a flowbench report on each runner. Flows matched to within 1%.

I'm not wanting to port into the manifold or offer too much in the way of add-on options to the manifold unless the companies I've spoken to want to sharpen their pencils some more. The idea is to get the manifold available to the community affordably, and if people want to extrude hone, HPC, polish, twin TBs or whatever, then they're free to do it off their own bat.

The only likely inclusion is wet bead blasting to close up the pores on the surface to improve presentation but more importantly make the unit less susceptible to penetration by dirt and oil etc. Closing the pores up will make the manifold surface significantly easier to keep clean. I had the proto bead blasted last week and the improvement in surface quality is impressive. Pics soon!

I will post a pic or two on thursday once it's 'in the car' for evaluation. I've just finished working 29 days straight, had sat off, and am working again now until tues. I'm just stuffed atm.

yeah thats fair enough. the new manifold looks real proffesional, well done! i bet your glad you abandoned the previous design when you did!

i bet your glad you abandoned the previous design when you did! You've no idea how glad I was to see the end of that version. I must have been having and out-of-body experience when I thought that was feasible...:fruitcake

Ok, on-car update. 5spd auto in my AWD. No extractors.

The smaller ports at the flange that mates to the lower inlet plenum helped the 1000-2800 band with my 0-100km time dropping from 8.7/8 - 8.55 on an average of 5runs. But I think they are causing too much harm in that it doesn't pull noticably harder above the 3000 mark. Smooth but not exciting. Can feel the motor being held back up top from 5800+. May require a larger plenum - will mill the ports first and re-evaluate. Fuel economy was unchanged but showed potential when on the open road. Must say overtaking in "D" seems more purposeful. Less downchanging. Any mid to high rpm gains atm are a function off the larger plenum volume.

So that's all good: I learn't what I wanted to know and can now mill out the ports to 39.5-40mm diameter as per my welded manifold and the lower inlet manifold flange.

The mold is easily adaptable to produce the larger port sizing.

The other thing of interest is that custom support brackets for the rear may be required as the stock ones are not aligning well and there was insufficient meat in the plenum to tap and thread the drivers side support. I am looking at the plenum mold to see if that can be amended, I think it can be done simply enough.

I get the impression the drop-off in power above 5800rpm is largely a limitation of the factory cam profile. Although obviously breathing mods always help, I get the impression the top-end gain of the manifold will be truly stunning in combination with a cam swap, the extra flow capacity up top will be even better utlised with a cam swap.

Although I'm sure it'll be a great mod just by itself, as far as reasonably cheap n/a mods go a 0.2-0.3second 0-100km/hr or 1/4 gain from such a mod by itself is fantastic. I wonder how that translates to our FWD manual magnas.

What do you think regarding this Ian?

It's looking good, the end is in sight :)

nice mate! Can't wait! And i just started a full time job a few weeks ago! yay for money! hahaha

Love the comment about the operating range improvements.
As I also have an AWD I am painfully aware that the transmission management always wants to have the revs down around 2000 araound town. You can feel the engine straining a bit to pull this combination.
Any improvement in the 1500 to 2500 range will dramatically improve driveability.

Keep us posted.

Most important one will be a before and after dyno curve to see what the low range gains are actually like. I suspect that it may not look a lot on the graph, but when calculated as a percentage improvement at say 1500 and 500 rpm increments may prove to be very usefull.

Keep up the good work.

Gerry

I get the impression the drop-off in power above 5800rpm is largely a limitation of the factory cam profile. Although obviously breathing mods always help, I get the impression the top-end gain of the manifold will be truly stunning in combination with a cam swap, the extra flow capacity up top will be even better utlised with a cam swap


I tend to agree with the thought that this enginge is at its capacity at 5800rpm.
Happy to hear about the low down rev range pull this has tho. 'bout the only thing i am missing now is a decent manifold to go harder off the line having an auto as well.

It's weird that I thought I wanted more low down but I haven't been that much fussed in it. Probably due to it not carrying thru into the mid and high with the present experimental port size/shape. The manifold is coming off tomorrow to mill the ports out and then reinstall.

I have been snooping around the mold and have about 7 changes I want to make to enhance the unit. More work, yay! :cry:

It'll be worth it!

It's weird that I thought I wanted more low down but I haven't been that much fussed in it. Probably due to it not carrying thru into the mid and high with the present experimental port size/shape. The manifold is coming off tomorrow to mill the ports out and then reinstall.

come up here and put it on my car and we'll see if there is a change:shifty:


It'll be worth it!

sure will

Hey ezboy, was just wondering if you had a pod on that test car, if so, what does that little beauty sound like compared to the stock number?

cheers

Any mid to high rpm gains atm are a function off the larger plenum volume

Recommendation is to make the total volume of intake system 2.5 times the engine cc - so simply ensuring the V of new plenum covers that difference u will be on the right track.
I did some calculations previously and ended up with requirement for increase of 1.5-1.8 liters for the plenum chamber V. How much bigger is your design frm the std plenum?

1st prototype had a plenum volume of approx 3.4L, the factory one is like 1.85L. The cast manifold will be in the 3.2-3.4L area since not many of our cars are revving above 7000 ;)
Getting some changes made to the mold to correct some oversights and lazy molding from the guy I paid good, borrowed $$$ to :doubt:

I am not sure of the intake system on the test mule - since it hasn't been tested yet! The old welded proto had a Pod Box so the intake noise was reduced, but take the lid off and the pulses of air hoovering down each runner drown out the pod's sucking :D

Sounds (not literally) good to me!
We just wait a bit more then. :)

nice work. I would be interested in getting one of these.

Hey EZ Boy,

Talk to me, any struggles making progress?

Have made some serious changes:

1) Raised the runner's path to clear the rear plugs
2) Improved the runner union above the port
3) Enlarged the plenum volume to 3.38L with some scratching at the walls to go
4) Reduced the wall thickness in many areas to reduce weight and aluminium used
5) Numerous other touch ups and reviews to prep and pouring of the casting.

Hope to cast another proto this wk or early next.

Taking it's sweet time I know :doubt:

As for an ceiling of 5800rpm on the motor I strongly disagree - the limitation is definately intake. My old faithful welded prototype of 2005 would rev to 7000 and was still pulling hard upto 6300-6600. Would be a top mod for a track car! Fun on the street but a real bonus off-road imho. What facinated me so much about the welded proto's performance was I was running stock cat and NO extractors.

thats awesome. i cant wait.
would love to see a dyno for it once its complete.
really curious on how it preforms.

what sort of price will you be looking at?

Have made some serious changes:

1) Raised the runner's path to clear the rear plugs
2) Improved the runner union above the port
3) Enlarged the plenum volume to 3.38L with some scratching at the walls to go
4) Reduced the wall thickness in many areas to reduce weight and aluminium used
5) Numerous other touch ups and reviews to prep and pouring of the casting.

Hope to cast another proto this wk or early next.

Taking it's sweet time I know :doubt:

As for an ceiling of 5800rpm on the motor I strongly disagree - the limitation is definately intake. My old faithful welded prototype of 2005 would rev to 7000 and was still pulling hard upto 6300-6600. Would be a top mod for a track car! Fun on the street but a real bonus off-road imho. What facinated me so much about the welded proto's performance was I was running stock cat and NO extractors.


Sounds good Ian, keep us posted!

Enouraging to hear you think the manifold extends the powerband significantly on it's own, that really does make it a terrific mod, even just by itself. Gonna be interesting to see how it behaves in conjunction with a mild cam upgrade. Awaiting with much anticipation :)

Just when I was about to give up - you pulled me back in again. :cool:
My BDay is coming soon - hinthinthint :)

Sounds good Ian, keep us posted!

Enouraging to hear you think the manifold extends the powerband significantly on it's own, that really does make it a terrific mod, even just by itself. Gonna be interesting to see how it behaves in conjunction with a mild cam upgrade. Awaiting with much anticipation :)

much much anticipation:drool:

Changes look good in the fire box, will pour monday :dancin:

picsorban!!!!

picsorban!!!!

HAHA Starts rant....:bowrofl:

Hang onto something - here are the raw pics of the 2nd prototype. The casting will be done in a different core medium for production items and will be blasted etc.

As discussed previously the plenum is now much larger (3.4L vs 1.8L stock), the runners clear the rear plugs, the runners are now longer (*just*) and a few other details. I need to make some mods for bolting for the production items which is easy done now we're at this point. Need to clean up the faces, drill and tap, knock out some dags in the plenum and evaluate on-car. :coffee:

Enjoy this soft porn:

3.4L vs 1.8L stock

That freakin ROCKS! The pics look great! You're a freakin genius!

:D

You're a freakin genius!

Only if it works (holds breath...) ;)

Can't wait to see how the new revision performs.

The EZ is a nice touch too :)

Brilliant.
That is a very neat casting for its complexity.
Pity that it can't be in cast iron then we could make it for you on a Disa.
± 0.2 mm easily possible.

That's why I had the little dig about the pictures.

Fantastic progress.
Next year, maybe I'll be able to get the funds from her indoors to have one.

With the changes you have added I suspect that this will fill a fiar bit of the torque curve "hole" low down.
Add a flowed throttle body - whee!!

Gerry

I can perhaps see some broken auto gearboxes coming from this mod aswell. Oh well, well worth it IMHO. :)

The EZ is a nice touch too :)

Gotta protect my investment :D

The manifolds will be serial numbered too. Sorry the #1 plate is going to AMC for *raffle*.

The #0000 plate is MINE.:cool:

shouldn't the EZ be on the other side??
it looks really good. i wouldn't mind people seeing it at all.

shouldn't the EZ be on the other side??
it looks really good. i wouldn't mind people seeing it at all.

The intention was to make it as stock looking as possible as people were nervous about insurance/cops etc.

oh right. i don't see anything illegal about a custom manifold though..

i still love the look of the ones that EZ has set up in his car.

oh right. i don't see anything illegal about a custom manifold though..

i still love the look of the ones that EZ has set up in his car.

Its not illegal as such, but any mod makes insurance a little harder and cops pick on you more...

man that looks hot as, put me down for it as well as a o/s throttle body!!

my rebuild is re - starting

Only if it works (holds breath...) ;)
That's looking really good hey. Nice pun too.

You know, you're making it really hard for me to do the right thing by my impending mortgage :rant:

oh right. i don't see anything illegal about a custom manifold though..



By the pics, it doesn't have a flange to attach the EGR pipe to. So by fitting it to a later model 3rd gen you would be disabling a factory fitted emissions control system.

Having said that;
Anyone with aftermarket headers fitted to an EGR equipped car has most likely already had the system disabled, and
it would need to be a really anal traffic cop / inspection officer (who knew magnas back to front) to even pick up that it had been disabled.

By the pics, it doesn't have a flange to attach the EGR pipe to. So by fitting it to a later model 3rd gen you would be disabling a factory fitted emissions control system.

Having said that;
Anyone with aftermarket headers fitted to an EGR equipped car has most likely already had the system disabled, and
it would need to be a really anal traffic cop / inspection officer (who knew magnas back to front) to even pick up that it had been disabled.

Ya know its funny BB my EGR has been "disconnected" for nearly 5yrs now, back 2003 my car was unlucky enough to be tested in a roadside EPA emissions test and passed....... Just, despite the EGR gone, maybe my modded ECU tune helped.

Hang onto something - here are the raw pics of the 2nd prototype. The casting will be done in a different core medium for production items and will be blasted etc.

As discussed previously the plenum is now much larger (3.4L vs 1.8L stock), the runners clear the rear plugs, the runners are now longer (*just*) and a few other details. I need to make some mods for bolting for the production items which is easy done now we're at this point. Need to clean up the faces, drill and tap, knock out some dags in the plenum and evaluate on-car. :coffee:

Enjoy this soft porn:

Hey Ian,
my work has a new cnc mill out at the factory. If you speak to dave he may be able to machine the faces and drill and tap them for you!!

By the pics, it doesn't have a flange to attach the EGR pipe to. So by fitting it to a later model 3rd gen you would be disabling a factory fitted emissions control system.
*Hugs his 3.0l engine*

Ya know its funny BB my EGR has been "disconnected" for nearly 5yrs now, back 2003 my car was unlucky enough to be tested in a roadside EPA emissions test and passed....... Just, despite the EGR gone, maybe my modded ECU tune helped.

Gee thats lucky. Mines been gone for years now too (on both my cars), but I'm not overly worried about it. I've never even seen a "roadside EPA emissions test" here in Qld, but I know some states are alot tougher on those sorts of things than others.

i just get epa notices, you get that though when you are at 104 db and legal is 96.

By the pics, it doesn't have a flange to attach the EGR pipe to. So by fitting it to a later model 3rd gen you would be disabling a factory fitted emissions control system.

Having said that;
Anyone with aftermarket headers fitted to an EGR equipped car has most likely already had the system disabled, and
it would need to be a really anal traffic cop / inspection officer (who knew magnas back to front) to even pick up that it had been disabled.

My first post stated clearly that EGR was not supported. Several reasons really:

1) It's a pita to add it to the mold esp given the number of arms I've had to twist and re-twist to get this made. Mention "Magna" and everyone's eyes glaze over and the onlookers depart....:doubt:
2) Serious players will have already plugged their headers anyway.
3) People are most welcome to remotely mount their EGR tackle, I've done enuf I think.
4) People should keep their oem plenum tucked away safely in the shed for just such a drama if required to correct a defect from a roadside test.
5) Go a piggyback and tune the fuel out OR
6) Grab Barry's fuel rail kit when you swap plenums out.
7) The bigger plenum etc hasn't been measured to position the oem EGR pipe yet so can't retrofit to the plenum without some on-car time etc. May supply as additional extra, maybe.


Screamin TE: Got a nice mill at Dad's, not a big fancy CNC thingo but will do the job. But if all fails I know where to find you. Btw, thanks for the loan of the 'turtle shell'. When are you guys going to do a run of forged pistons and rods for the club? ;)

Wwwwwwooooaaaahhhhhhhhh!!!!!!!!!!!!!!:D
Is it ready yet?
Is it ready yet?
Is it ready yet?
Is it ready yet?

W*H*A*C*K

Auto gear box detonating.....????? Oowwwh - still in fresh memory from June this year. 2500 bux later.... :cry:

Redav - when hugging your donk, do u wrap arms around the plenum or the whole lot, diagonally from right?

Check ya pm's dude :)

Ya know its funny BB my EGR has been "disconnected" for nearly 5yrs now, back 2003 my car was unlucky enough to be tested in a roadside EPA emissions test and passed....... Just, despite the EGR gone, maybe my modded ECU tune helped.


egr only works a. when engine hot
b. when cruising.

epa only test at idle and at 2000rpm in both cases the egr is not working anyways.

you do NOT lose any power from a egr.

egr only works a. when engine hot
b. when cruising.

epa only test at idle and at 2000rpm in both cases the egr is not working anyways.

you do NOT lose any power from a egr.


The EPA tested my car at idle, 2500 and 4800rpm plus they revved and quickly released the throttle to in there words "cycle" the EGR valve.

We used to do similar at MMAL when we were dynoing development motors that were undergoing ADR simulation testing.

EGR works by vacuum on a diaphram which opens when you lift of the throttle or any other time when there is enough vacuum to open it, this allows exhaust gases back into the inlet plenum, this exhaust gas mix polutes the incoming air and also dilutes the amount of "clean" air the engine takes in. EGR is there to help lower NOx emissions.

Heres a link about EGR: http://en.wikipedia.org/wiki/Exhaust_gas_recirculation

straight from the manual..

Looking good. I might have missed it before, can the Verada engine shroud still fit? I think the wagon NEEDS this and the TB mod.

Ian has borrowed a cover off of me. I believe it is to ensure that everyone gets the OEM look.

Redav - when hugging your donk, do u wrap arms around the plenum or the whole lot, diagonally from right?
:bowrofl:

Not the plenum... arms aren't long enough...

*** UPDATE ***

The OEM cover needs a slight nick on runners 1 & 6 to get the fit due to the massive height of the dual runners (see pics).

The manifold is heavier so custom brackets are being made.

I need to clean it out and get it on the car. That's where it's upto :dancin:

Thats ****en insane man!

WOOHOO!! That looks great! Progress is being made :D

Freakin Awesome!

Keep up the good work mate :D

looks scary, i assume screamin TE will be getting one on top of his crazy quad cam donk

looks scary, i assume screamin TE will be getting one on top of his crazy quad cam donk

He might need a BA V8 bonnet to get it all in there!!

YES im in cob. 3.5ltr 3rd Gen Manual YOU BEAUTY!!!! :2cool: :2cool: :2cool:

He might need a BA V8 bonnet to get it all in there!!
chuck it all together, then worry about the bonnet, minor detail!

chuck it all together, then worry about the bonnet, minor detail!

:bowrofl: :bowrofl: :bowrofl:

i say forget the bonnet altogether. may be a possible chance of a defect. but at least the manifold will fit.

I'll just carve a hole in it and let it poke through like the old bug catchers.

**** HERE IT IS!!! ****

It idles sweet, it revs freely, it pulls hard from 3k to 7k. Downshifting (AWD 5spd tippy) anytime above 4k drops it back into the power band. You can now drag race with the air con on ;)

Very smooth and power delivery is linear. Screamin TE drove it briefly today so be good to have a valued independant assessment for members.

As you can see some minor mods need to be made to improve presentation andI will get it dyno'd in January to show people what this mod does - in black and white. :cool: :dancin:

Fuel economy seems unchanged at the moment, so when I stop getting up it I will see how it looks. Mindful I DON'T have extractors or CAI atm.

Thank f*** this worked today 'cause I was sooooooooo divorced if it didn't.


COST? The good news is that it's well on track for budget and apart from any blow out in blasting finish, they will still be $850 as previously indicated.

Well done EZ and congrats for getting the goods to the masses. Great that you got the performance out of it as promised.

Sounds awesome.

Well done EZ and congrats for getting the goods to the masses. Great that you got the performance out of it as promised.

Sounds awesome.

Should fit a 380 too with some fiddling :D

:D that is all i will say at this time!!!

:D that is all i will say at this time!!!
im glad your referring to the smiley you posted and not your avatar

wow another usefull bit of input, what would we do without you toocky, congrats on the manifold, looks great and seems like the results speak for themselves

wow another usefull bit of input, what would we do without you toocky, congrats on the manifold, looks great and seems like the results speak for themselves
wow good work at throwing off at me for posting exactly what you just did but in a different way douche bag. i was saying that im glad the manifold actually does work and has obviously impressed TE which by me sayin that im glad that he was referring to the smiley with a massive grin compared to his almost emotionless avatar is saying that im glad that EZ's work has paid off

seriously go kill your self

whatever dude, dont spam, weve had enough of it.



seriously go kill your self

might pass on that one for now

Good work there. Lots of effort gone into it and the results look like they are there. Now if you could only do one for my Pajero :shock:

wow another usefull bit of input, what would we do without you toocky,

Does it come in pink? :confused:

Excellent stuff EzyDude. Been long time coming. Having been one of 3 original deposit makers last year, do I have the benefit of jumping the queue and be the first one on your order list..... :) :) :) :)

Brilliant,
Roll on 2008, Rolling road comparison results and mass production.

Gerry.

**** HERE IT IS!!! ****

It idles sweet, it revs freely, it pulls hard from 3k to 7k. Downshifting (AWD 5spd tippy) anytime above 4k drops it back into the power band. You can now drag race with the air con on ;)

Very smooth and power delivery is linear. Screamin TE drove it briefly today so be good to have a valued independant assessment for members.

As you can see some minor mods need to be made to improve presentation andI will get it dyno'd in January to show people what this mod does - in black and white. :cool: :dancin:

Fuel economy seems unchanged at the moment, so when I stop getting up it I will see how it looks. Mindful I DON'T have extractors or CAI atm.

hey EZY you say it pulls hard from 3000rpm up but was there a noticable differance from the start or down low...maybe from third at 50kmh? Seeing as though your test mule was an auto, and a poll we had suggested there are almost as many autos as manuals(91-104 with responses) us auto drivers are keen to hear how the take off is.....granted you arre dynoing it, but thats not where you feel it...you know what i mean

Okay questions:

Killer: The good thing about these manifolds as opposed to the High Flow TBs I do is that the foundary can make them in any volume I need them - the TBs rely on the exchange return timeframe. But yes, expect your earlier commitment to carry weight this time round :cool:

spud100: Rolling tests haha! I we supplied 2x Magnas (1 with and 1 without manifold) to Wheels or Motor magazine, the commodore will still come out ahead :nuts:
My experience with traffic and highway driving in my AWD has been impressive. Give the car has NO extractors, stock cams, stock ecu, no fpr etc etc. Smooth acceleration in all gears, best acceleration is when the rpm is 3000 or above - which is easy to do with a down change in traffic. Even so, I find the AWD clinging onto the higher gears much easier than it used to. AWD owners know the dreaded '5th gear 50kph car not moving, tranny not downchanging' bull**** the car does - at least now the car accelerates!

In the lighter fwd cars with less drivetrain loss, the extra power across the board will definately impress. It's a deadset *new* car now.

Magtone: I think the 4spd autos will work very well with this mod, you'll get sick of the TCL coming on all the time :D

To be fair there is still a noticeable slow/dead zone from idle to 2500, but there is certainly more pull than stock. There is a refined feel to the motor if that makes sense.

A manual in 3rd at 50km will certainly get mobile quickly. My TF with old welded up prototype was getting wheel wobble at 80kph in 3rd from a 200000km 3L motor and 16s.

I'm really excited to see how this goes on Chisholm's car for the dyno runs and with some track work. Quarter mile regulars will be very happy with the extra ponies. Be handy to see the dyno and maybe hold the gears a little longer down the quarter.

And as before, you can hear the air pulsing down the runners with the bonnet up. I know, it's for the carpark kids ;)

EZ is the gap between fuel rail and the bottom of the manifold still as std? I'm interested but my fuel rails are about 12-15mm higher than std. looks great anyhow:cool:

EZ is the gap between fuel rail and the bottom of the manifold still as std? I'm interested but my fuel rails are about 12-15mm higher than std. looks great anyhow:cool:

Just checked (people driving past thought I was pulling a shifty in an unlit driveway with torch and bonnet up!). There is more than 20mm clearance if the fuel rail height has been changed at either the injector OR the rail bolts. That should cover your situation I think.

Just checked (people driving past thought I was pulling a shifty in an unlit driveway with torch and bonnet up!).

lol . awesome thanks for the fast response.

Give the car has NO extractors, stock cams, stock ecu, no fpr etc etc. ...
In the lighter fwd cars with less drivetrain loss, the extra power across the board will definately impress. It's a deadset *new* car now.

This is exactly what I want to hear! I'm definitely going to have some money saved up ready and waiting for when these are released :)

needs a nsfw tag becuase this is porn.

I've put a touch over 420km on it now and if I drive *normally* my AWD is 10.9l/100km - down from 11.7-9L for the same trip. With a fair bit of squirting I was in the mid 12s per 100.

In my AWD I took a 90deg to get onto the new england highway - a rather sweeping turn, not a tight little thing - and the inside wheels lifted, which wasn't so unusual, but the front of the car lifted up and stayed up while I got upto speed. Felt like it was gunna take off :shock: I'm having a lot of fun with this atm - I'm gunna be secretly sad to bolt it onto the test car in a few wks for it's dyno run, and it's new home. A few hugs and tears until it's replacement is cast and dressed...... ;)

Sounds promising, Ian. Well done.

How's it go with fitted strut braces? I know we measured some heights at some stage. 3.5 and 3.0 catered for fine on all fronts (I'd imagine so)?

I'm gunna be secretly sad to bolt it onto the test car in a few wks for it's dyno run, and it's new home. A few hugs and tears until it's replacement is cast and dressed...... ;)

Don't worry Ian, I'll take good care of it:bowrofl:

Ill be very interested to see a dyno graph of one of these manafolds on and off a stock magna and on and off a ralliart...

Id be very interested in this mod...

Regards
Alex

Don't worry Ian, I'll take good care of it:bowrofl:



Sharpens lockpics!!!! HAHAHA

Sounds promising, Ian. Well done.

How's it go with fitted strut braces? I know we measured some heights at some stage. 3.5 and 3.0 catered for fine on all fronts (I'd imagine so)?

I sure hope it fits - it was one of the original prerequisites for the mold-maker; that any increase in height over the stock plenum be kept to a minimum. The increase in plenum volume has been gained in width and depth towards the firewall mostly.

You can see in the photos that the plenum top is almost level with the strut towers on the 3.5L in my awd. The 3L will obviously be roomier.

I need to design a suitable bracker system for the rear of the manifold to contain it's considerable weight. I have a design in my head, just need to get some aluminium bar/sheet when the suppliers reopen. Going for a one-size-fits-all bracket so aftermarket value is retained between 3L and 3.5L private sales.

A big thanks to everyone on AMC for putting up with this long-winded process. It's an enormous relied (esp to my marriage) that there is some tangible fruit finally.

Btw, chomped a VS ute at melbourne street lights this arvo. Go Magna power!!

[QUOTE=EZ Boy]I sure hope it fitsQUOTE]


If you need a car to test fit it with a strut brace let me know i can pop around any afternoon.

[quote=EZ Boy]I sure hope it fitsQUOTE]


If you need a car to test fit it with a strut brace let me know i can pop around any afternoon.
Ditto...

You know BJ31OS and Ian... We should have our own meet up day one time...Since we all seem to be from the same area...

Ian, with the hight, have you taken into account engine movement under load, and the additional stress the manafold may cause cause of its weight...

I know it seems far fetched... but what about unbalencing the engine at high RPM...? Due to its conciderable weight and hight, you think it could introduce a werid harmonic to the motor? (the motor does move back and forth under load/high RPM)

Thoughts?

Regards
Alex

[quote=BJ31OS]
Ditto...

You know BJ31OS and Ian... We should have our own meet up day one time...Since we all seem to be from the same area...




sounds good to me

[quote=BJ31OS]
Ditto...

You know BJ31OS and Ian... We should have our own meet up day one time...Since we all seem to be from the same area...

Ian, with the hight, have you taken into account engine movement under load, and the additional stress the manafold may cause cause of its weight...

I know it seems far fetched... but what about unbalencing the engine at high RPM...? Due to its conciderable weight and hight, you think it could introduce a werid harmonic to the motor? (the motor does move back and forth under load/high RPM)

Thoughts?

Regards
Alex

Won't change the rotating mass, if the engine mounts are slightly worn I still wouldn't perceive any dramas. There isn't actually that much more height surprisingly. The new manifold weighs in around the 10kg mark. The revised bracket will be more than adequate since it is bolted hard onto the motor at both sides of the rear head.

Atm I'm working 7days a week but a get together and tinker is always a good excuse for some rpm and a few beers :D

[QUOTE=Tonba]


sounds good to me


wonder how many of us are from the newy area?

Apparently Im not cool enough to hang with Alex, Brad and Ian. :cry:

Apparently Im not cool enough to hang with Alex, Brad and Ian. :cry:
:stoopid:

:stoopid:

Your always welcome to meet up with us Screamin TE

Apparently Im not cool enough to hang with Alex, Brad and Ian. :cry:

LOL...lol

Sorry guys (Screamin TE & Gas-Hed)... I forgot how close you guys were...Where do you guys live anyways?

We all really should meet up somewhere and have a tinker and a bit of a drive one afternoon or something...

There are what, 5 of us in the Beresfield~Maitland area...

Regards
Alex

LOL...lol

Sorry guys (Screamin TE & Gas-Hed)... I forgot how close you guys were...Where do you guys live anyways?

We all really should meet up somewhere and have a tinker and a bit of a drive one afternoon or something...

There are what, 5 of us in the Beresfield~Maitland area...

Regards
Alex

make that 6 im just out of maitland lol

Okay questions:

Killer: The good thing about these manifolds as opposed to the High Flow TBs I do is that the foundary can make them in any volume I need them - the TBs rely on the exchange return timeframe. But yes, expect your earlier commitment to carry weight this time round [

:D :D :D :D :D

And good to hear about strut brace and rear bracket issues too!

Me & BJ31OS live in the Terrace (together).

Screaming TE (Chris) lives in Thornton.

Fuel economy update: Reset the fuel average on the trip computer at McDonalds at Singleton, drove towards Branxton turned down Hermitage, gunned it along and turned into Old North Rd, held it in 3rd (5spd auto) and raced it between 40kph and 120 along and up thru Sweatwater estate, back onto Old North towards Rothbury, to Greta via Tuckers Ln and back to maitland. Av fuel 11.1L/100km. Moderate rain, dirt roads, 3rd gear and loads of torque! Drove to Belmont and back next day. Av fuel econ 10.6L via F3, speers pt, elebana. Normally I get 11.3-11.7 after this sort of trip.

I can deal with that :cool:

Stats are looking better and better....

Sorry if this has been asked million times, but this wont fit a 2nd gen V6 12 valve?eh?

Can the throttle location be moved to the other side?

Stats are looking better and better....

Sorry if this has been asked million times, but this wont fit a 2nd gen V6 12 valve?eh?

Can the throttle location be moved to the other side?

Cut and weld - it'll fit a camry if it has too. I'd like to see it on a 2nd gen 12v but I can't afford the modding atm. I have a 2nd Gen plenum (thanks Paul) so the odds of machining a lower flange are good, maybe there's hope for it. I'll start a thread in 2nd gen and gather info.

So it will still be over the back of the motor? not the front? havent seen a gasket to see if it will spin 180deg....

So it will still be over the back of the motor? not the front? havent seen a gasket to see if it will spin 180deg....

http://www.aussiemagna.com/forums/showthread.php?t=55123

I'll get out of the big boys area now...::gtfo: :D

sorry, im a bit (a LOT) out of it.
hows this project goin? is it in the production/selling to other members stage yet? what the current figures and the like.

still in the development/testing stage on EZ-002P (p for prototype).

Some even say that the life of EZ-001P is in this manifold........

ahhk sweet thanks.
also, do u know anything about the manifolds and stuff available in the merchandise?

Some even say that the life of EZ-001P is in this manifold........ If you listen carefully you can even hear it's ghost.....

still in the development/testing stage on EZ-002P (p for prototype).

Some even say that the life of EZ-001P is in this manifold........


Rehersing for Top Gear Aus eh??:bowrofl:

hehe top gear.

my OTHER question (i just thought of it then haha) is this:

how do these go legality wise? lol. i dont wanna buy one when they are all sweet to go, then find out the boys in blue / the rta dont like it. lol
are they street legal, simple as that?

thanks!
you rule ezboy
andrew

IMHO the average roadside bluey will know no different.

If the EPA want to be asses they can emmissions test and you may still pass. as i can't see it damaging the emmission levels much. All pollution gear is still in place and workin.

If anything it is probably more efficient than the stock when tuned.

IMHO the average roadside bluey will know no different.

If the EPA want to be asses they can emmissions test and you may still pass. as i can't see it damaging the emmission levels much. All pollution gear is still in place and workin.

If anything it is probably more efficient than the stock when tuned.

Actually it has been mentioned the E.G.R will not be able to be used as no allowance has been made for it. Unless you make something up yourself it will not be able to be refitted. An aftermarket computer may assist with the emission levels, as one member here was emmision tested after removing egr, but also passed possibly due to the piggyback tuning.

Actually it has been mentioned the E.G.R will not be able to be used as no allowance has been made for it. Unless you make something up yourself it will not be able to be refitted. An aftermarket computer may assist with the emission levels, as one member here was emmision tested after removing egr, but also passed possibly due to the piggyback tuning.

sorry what do u mean by e.g.r? and what is not able to be refitted?

sorry what do u mean by e.g.r? and what is not able to be refitted?


Exhaust Gas Recirculation.

Exhaust Gas Recirculation.

yep. it is the pipe that goes from the exhaust pipe to the intake plenum that wont be fitted.

is it a bad thing?
or is it just a bad thing legally.
what does it do?

is it a bad thing?
or is it just a bad thing legally.
what does it do?

It recirculates burnt exhaust gasses back into the air in the plenum to be reburnt in an effort to reduce emmissions. If you have extractors, it most likley will not be reused. Some are as some exctractors have provision if the hole is drilled out. it can be blocked off, but as mentioned it may present an epa risk, IF you get pulled over.

Have these been flow tested in comparison to the standard item?

The chances of getting tested IS RARE! cops will pull you and defect for what they can SEE is wrong, rims, exhaust, too low etc...

To get emmisions tested you really have to piss som1 off bigtime. It's mainly noise that attracts attention. I have been put over the pits and they didn't do an emmisions test. but defected me for a list of other things.

I think its more there for BIG trucks.... Plumes of smoke everytime they take off.

Re: EGR support: It was too fiddly to incorporate into the manifold but members are free to weld their own support in for it. The EGR pipe also transfers massive heat to the plenum, not great for performance. On the other hand, TE & TF don't have EGR so are perfectly legal with this manifold in my opinion.


Have these been flow tested in comparison to the standard item?

I don't believe that a flow test will tell much about the manifold. Consider these facts:

OEM Manifold:

The plenum is small (1.8L) so wont flow high numbers / wont support high rpm power.
Can support low and mid range power *just* :P
The runners have large diameters (V=12.5cm2) that can flow high numbers / good for high rpm.
Can't support low rpm power - larger diameters have slower air speeds so low to mid rpm efficiency is compromised. I believe that a lot of the sub-2500rpm dead spot is caused by the inability of the oem manifold to supply air efficiently to the motor. Along with the dozy camshafts....

So what can it do if the plenum wont support high rpm and the runners wont support low rpm? The TB will support both. Seems like the whole damn thing was never thought about.


MY MANIFOLD:

The plenum is large (3.4L) and will flow high numbers at high rpm / supports high rpm power.
The plenum holds a large volume available for instant air demand - good throttle response.
The single large runner is replaced by 2x smaller runners that have a combined cross (2V=14cm2) section that outflows the large OEM runners BUT being smaller have a higher air speed.
The higher air speed allows excellent low and mid efficiency and power generation while MAINTAINING the ability to supply high flow volumes for high rpm AND high rpm power.

Summary: Improved low/mid efficiency is evident by the improved fuel economy. Power comes on hard with the cams at 3000rpm on the dot, and hold to 6500rpm.

The biggest weakness is the cams. Get them to come on at 2500rpm and heaven will be on earth :cool: since most auto stallys are between 2600-2800 so that rpm would be smicko.

Even with stock cams the autos will be very quick and responsive, Manuals will be able to haul in in most gears and road speeds, downchange only if you want to.


Dyno run coming within the fortnight. Trying to get some time at RX Engineering near Newcastle.

Re: EGR support: It was too fiddly to incorporate into the manifold but members are free to weld their own support in for it. The EGR pipe also transfers massive heat to the plenum, not great for performance. On the other hand, TE & TF don't have EGR so are perfectly legal with this manifold in my opinion.


sweet thanks.
lol, next proto goin well?

sweet thanks.
lol, next proto goin well?

The latest pics are of Proto 2, proto 1 was thrown back into the furnace after notes were taken. Proto 2 is practically production ready. I am going to make some cosmetic changes along with an appearance upgrade so that people know it's MY manifold under their bonnet not just an oem item. Will still look stocko, but Magna people will know. Additionally this will help the cast pouring and give a better finish/presentation to the final product.

Once these changes are made, I will start taking orders. In the meantime, I am arranging a before and after dyno run so power curves can be analysed and people can see a black & white improvement so they can see what their $850 buys.

The latest pics are of Proto 2, proto 1 was thrown back into the furnace after notes were taken. Proto 2 is practically production ready. I am going to make some cosmetic changes along with an appearance upgrade so that people know it's MY manifold under their bonnet not just an oem item. Will still look stocko, but Magna people will know. Additionally this will help the cast pouring and give a better finish/presentation to the final product.

Once these changes are made, I will start taking orders. In the meantime, I am arranging a before and after dyno run so power curves can be analysed and people can see a black & white improvement so they can see what their $850 buys.

cool.
sounds interesting.
i wish i was rich.
then i could buy you.
"EZ Boy slave - mod my car"
haha.
but seriously - good luck
im interested (thats not a confirmed buy ;) )