Intake plenum and 911 throttle body

[Ben006]

I will make one, test it, then, I can make as many as I want with a 2 week delay between

the material will be nylon, I tested it up to 240F without problem so I'm not worried about it, it will be 4mm thick (3mm for the one I already have, and tested) and I will wrap it with heat insulator for further protection

Ben

[jaykay]

Nice design! Has the bend to the left been designed for use of the stock 3.2 intake pipe? Does have it have captured nuts as would be found in a stock piece? 74mm TB?

The material also needs to be impervious to oil..

[Ben006]

The material will resist to oil and fuel

I don't know yet wich intake pipe will fit.
I tought the 3.2 used the same 68mm TB as the 2.7 ?

The nuts are hold in place in four hexagonal holes in the back of the mouting part.


Ben

[jaykay]

Originally Posted by Ben006

The material will resist to oil and fuel

I don't know yet wich intake pipe will fit.
I tought the 3.2 used the same 68mm TB as the 2.7 ?

The nuts are hold in place in four hexagonal holes in the back of the mouting part.


Ben

Yes you are correct. I am just hoping for/to: use the stock 3.2 intake pipe with and adapter on the end along with a 74mm TB; outlets matching the intake plenum dia.; an AOS port that matches the stock location, so that a stock AOS hose can snap right in.

your angle looks pretty close to stock so the stock pipe looks promising....trust me when I say that this will be a big plus.

You could just 3D scan the stock pieces and then bring them into your software, modify to suit a 74mm TB...optimizing bend radii where possible....hmmm sounds like a business op

[Ben006]

Hi !

Finally, after tens of hours behind the screen and in my engine bay, I think I have the right shape !

It has the same angle that the stock one has, so it must clear everything in the engine bay, it has the largest radius possible without affecting the fitting (larger the the stock one).

I added two ribs on each side to have a better sealing with the boots.

A groove in the mating surface to make applying silicon sealer evenly (I tossed the idea of using the Porsche seal, it's going to be just as good, but 4 times cheaper to make and change (20$ for the OEM TB seal...)).

I tilted the EVAP connector to be as close as possible to the stock location (do you know where I can get a new hose for this ? mine broke ...)

It's also 1mm thicker that the first one I made, so even stronger and resistant to heat (I will wrap it in heat shielding tape anyway).

It won't be black as the first one, but white. Why ? cheaper, and it's not the same black as the stock parts so ...

Finally, for information, nylon as been used for timing sprocket on some OHV engine, so in the engine bloc heat !
I think I will be safe in the intake

Oh and, it does not have the wedge but I can easily make one with a wedge !





Ffffff I'm really stressed to now if all my measurement are right ^^


Ben

[BoxsterSteve]

Ben, buddy, pal,
how much will one cost me?

[Ben006]

around 300$ shipped in the US.
I will also design one for the 83mm TB soon.

It's not "cheap", but still a fraction of what an IPD costs, and the benefit of having the same shape as the original one.

It will also depend on what I will use for the intake tube and if I include one or let you decide !
So I can't tell you a definitive price right now, but it will be around that.

Once I will have the actual parts in my hands, then installed in my car, I will be able to be more accurate

Ben

[Ben006]

A laser scanning tool costs more than my car ^^
But I don't need one

If I had the plenum out of the car (I should have bought an used one... but didn't want to spend too much money, and at the time, I thought that a straight one could fit ...) I could have easily replicate one :/

the stock 3.2 and 2.7 intake pipes are the same too, right ? problem is that the diameter start to decrease immediatly after the MAF from 76mm to ~70mm at the TB.
But I will figure it out

The outlets are the same diameter inside (1mm more outside, with a taper to slide them easily into the boots).
for the AOS, it should clip back on without problem (the only problem is the plastic hose is easy to break).

So I think I'm pretty close to your requirement

[Ben006]

Hi !
after months of designing and two weeks of waiting ...
here is the plenum





The added thickness made it really stiffer

I can't test it immediatly, my instructors at school want to see it ! and my CEL is on... so it doesn't makes sense right now.
so end of next week for the results

But I am really confident with it !

Ben

For the intake tube, I think I'm going to try the AirAid UBI kit

[jaykay]

Looks very nice!!

[Pdwight]

So this is similar to what Pedro sells ??

[Ben006]

Originally Posted by Pdwight

So this is similar to what Pedro sells ??

similar to the technotorque and IPD plenum and every other ones yes.

but it has the shape of the stock plenum, and retaine the stock evap hose (from AOS and plenum) and boots, just needs a new intake tube

[Pdwight]

Are you 3D printing these or 5 axis or ?

[Ben006]

thanks
Here's more



As you can see, I quite nailed it
I'm pretty proud of my self here, as replacating a part that complicated without having it with you is quite hard !

and even better... the evap hose clamp right on the new plenum ! (I will have to move the connection a little for the next ones, but it works !).

also, if you need another proof of the strengh of the part, I tried to stand on the old one... and it held my 175 pounds

I still have few more test to do, but I stay confident !

[Ben006]

3D printing!

[Pdwight]

How much are they going to cost ?

[heliguy]

Will you be testing this set up on the dyno? You mentioned testing in a week.

[Bfan]

I am impressed. Good luck with your CEL. They can be a PITA.
I might be interested in buying one from you if/when they become available although I already have a 997 Plenum. Your design will get the throttle body a little lower and my intake setup cleaner.

[Ben006]

Originally Posted by Pdwight

How much are they going to cost ?

As I say on the top of this page, around 300$, but I will depend on wethet I need to paint it or not

Originally Posted by heliguy

Will you be testing this set up on the dyno? You mentioned testing in a week.

I will try to get it on the dyno, but I can't garantee it :/
The testing will be more about reliability. I will put it on my car, and abuse it, then take it off and see if there is any problem.
Then, if I decide that it's good, you will get some

Originally Posted by Bfan

I am impressed. Good luck with your CEL. They can be a PITA.
I might be interested in buying one from you if/when they become available although I already have a 997 Plenum. Your design will get the throttle body a little lower and my intake setup cleaner.

I hope the sensor was the problem, will see next week if the CEL comes back.

Yes, the TB will sit at the stock location

Ben

[jaykay]

Nice ....so stock plenum boots can be used as the tee diameters match the plenums? This is a major potential loss area when using the 997 diverter tee.

If it puts the tb in the same you might be able to work with the stock 3.2 intake tube ....modified get the end

Originally Posted by Ben006

As I say on the top of this page, around 300$, but I will depend on wethet I need to paint it or not


I will try to get it on the dyno, but I can't garantee it :/
The testing will be more about reliability. I will put it on my car, and abuse it, then take it off and see if there is any problem.
Then, if I decide that it's good, you will get some


I hope the sensor was the problem, will see next week if the CEL comes back.

Yes, the TB will sit at the stock location

Ben