Intake plenum and 911 throttle body

[Ben006]

Hi !



So here it is, finally available!
A cheaper solution than the IPD, and better looking with a cleaner fitment than the 996 plenum.





First, let me clarify what it is and what it does:
This is a replacement intake plenum for all 986 boxster 2.7 and 3.2L, it allows the use of a 996 (or 997) Throttle, which has a larger diameter (74 vs 68mm), which in turns improves the amount of air flowing into the engine.
Here you can see the size difference! The 986 TB fits INSIDE of the 996 TB!


It is made of nylon plastic, which is resistant to oil, fuel and most solvent, and also quite strong (I can stand on it). It is not as stiff as the materiel used for the original parts, why is glass fiber reinforced nylon, hence the need for the stiffening ribs.
It is not molded, but made by Selective Laser Sintering, which is a 3D printing process that creates a part really homogenous inside, but with a rough surface. Far superior compared to the Fused Deposit Modelling used by all the "cheap" 3D printers.

Why not making it out of aluminum or have it molded in a superior material?
Simply because of the cost: I would need to make a lot of them to be able to sell them at the same price. Also, aluminum conducts heat better than nylon, which is not ideal for an intake system.

Why not use a Y shape?
The Y shape is patented by IPD, though there are ways to go around the patent, I'd rather keep the T shape and sleep in peace!

Why is it white inside?
I receive the part white, then paint it black with epoxy paint. I don't paint the inside so there is no risk of the paint being dilluted by the oil and gases coming from the crankcase ventilation then going through your engine and clog something.

What's included?
What you'll receive are:
-The new intake plenum
-Bolts and nuts for the TB
-A piece of hose for the crankcase ventilation (AOS connection)
-An EZ-coil to prevent the hose from collapsing.
-2 hose clamps

What else do I need?
To simply fit the plenum, you'll need:
-A 996 or 997 non-GT3 Throttle body (a used one is acceptable)
-A new intake tube, I'll discuss that later.
-RTV sealant to seal the TB on the plenum, it is a cheaper and more reliable method than using the 20$ Porsche rubber seal.

/!\ I don't recommend this as the first modification to your engine, alone, it won't performed at it's full potential. You need supporting mods: at least a K&N drop in filter, and a modified exhaust.

What results to expect?
I can only speak for myself, but there is a lot of feedback page 17.
I found a noticeable increase in torque above 1800 rpm then a flatter torque curve to redline, with less fading around 7000rpm. The torque dip around 3000rpm is greatly reduced.
It makes the car a lot more enjoyable for every day driving.
The sound changes too, the intake sounds deeper and louder.

I'll complete the thread when I have more time with the intake tube parts, more pictures, and installation tips.

You can always PM me

Ben

[Reebuck1]

I'm interested when you are done testing !! If you are looking for a tester I have a 986 that I installed a 3.4 996 motor. Goes like hell !!! Let me know. Thanks for the work !!

[Ben006]

Thanks

what throttle body you have on the 3.4 ?

I can make the same for any sizes of TB. !

[BrokenLinkage]

Very interesting! Addresses the inside corner flow issue, bound to be both lighter and a better value than the current aftermarket offering in aluminum. Keep us posted please as development proceeds!

[KRAM36]

The wedge doesn't make a big difference, but the Y shape does.

maf and throttle body diameter

From this thread.

http://986forum.com/forums/general-discussions/31693-maf-throttle-body-diameter-2.html

Most people just go with the 997 Distribution T because it has a very good Y shape to it.



If you can beat this price for a new 997 Distribution T and add more Y shape to it, I might be game on yours even though I already bought the piece.

99711041603 - DISTRIBUTOR TUBE - ES#1498085

[Ben006]

I won't beat the 54$ price you show :/
I didn't know that the 997 T worked for the 986 !

But I can improve even more the design, I will work on a more "Y-ed" design, to see what I can do

[The Radium King]

yup - hard to beat the price on the 997 part. however, that's for the 76mm tb; the only guys who make something for the 83mm gt3 tb are ipd, so if you can make something cheaper than them you will have an immediate market.

[Reebuck1]

I have a 74MM throttle body. How hard would it be to put a slight turn on the main intake port like stock Boxster TB have? That would really be helpful with the tight fits you end up with when installing a 996 motor in the Boxster motor bay..
If not I am still interested in the straight T you show below.

Ben, I am guessing you are doing this with a 3 D printer....Correct??

[Dlirium]

Subscribed! Ben, what is you background? What got you started on this project?

[Ben006]

Reebuck, can you show me how your engine bay looks ?

i can make any design for any size of TB it's made in nylon by stereolithography (the parts are more accurate and stronger than with the "hot wire deposit" 3D printers).

My background ? I'm an currently studying auto tech, and love the process of designing, making and testing things related to cars as far as my wallet allows me

[The Radium King]

hey ben - i'd like a plenum for a gt3 (83mm ID) tb - what dimensions do you need? I can get you ID and OD for the tubes that attach to the manifolds, distance between the two manifolds, ID of the throttle body, and details on the flange that fastens the tb to the plenum (hopefully it's standardised for all tbs). I would like as large a radius as possible on the bends - I can determine what length of plenum my engine bay can support.

[Dlirium]

Ben - you're pretty much making one of these if I understand correctly:

TechnoTorque

Do I have that right? I have a stock 2000 Boxster S, don't know what my plenum dimensions are - is that all you need to build one?

[Ben006]

No, these retain the stock TB but add a "divider", the first purpose of my is to use a bigger throttle body.

I took the measurement on my boxster 2.7 wich share its intake with the 3.2, so I already have the measurement.

I can make it any way you want, straight T, with a little turn, divider, no divider, wright anything on it ... etc

[Dlirium]

Originally Posted by Ben006

No, these retain the stock TB but add a "divider", the first purpose of my is to use a bigger throttle body.

I took the measurement on my boxster 2.7 wich share its intake with the 3.2, so I already have the measurement.

I can make it any way you want, straight T, with a little turn, divider, no divider, wright anything on it ... etc

Ah, got it. Well, good question. I don't know what I don't know on this. "A larger TB with better air flow" does sound good. I don't know if that translates to as to turns, dividers, straight, etc.

What are you recommending for increased performance? King, you seem to know a bit about this, what is you take? :-)

[ppbon]

Originally Posted by Ben006

No, these retain the stock TB but add a "divider", the first purpose of my is to use a bigger throttle body.

The TechnoTorque is a larger intake tee with a larger throttle body than the OEM.


Happy Boxstering,
Pedro

[Ben006]

Sorry I didn't know that they had the larger TB too.

[CraigM]

Very interesting. I think a 1 piece tube from MAF to new TB could be desirable as well. I have a 911 TB and 997 plenum in my garage, just have to get time to cobble the rest together.

My school (UTA) just opened a FabLab, gonna go learn how to use the 3D printers tomorrow night. Won't be at your level, but this definitely makes me more excited to go learn.

[Ben006]

The problem is that the tube will cost more than the T itself :/

Great to have a fablab ! We don't in mine

[KRAM36]

Originally Posted by Ben006

I won't beat the 54$ price you show :/
I didn't know that the 997 T worked for the 986 !

But I can improve even more the design, I will work on a more "Y-ed" design, to see what I can do

I didn't figure you could. What I would focus on is getting the Y shape better then the 997 piece, if possible shorten the distance from the TB connection to the Distribution T. On the 997 part it puts the TB very far out. I would probably forget about the wedge too.

This is what I would want for a Distribution T that accepts a 76mm TB and has the same diameter tube as the plenums.



One of the problems with the 997 piece is the larger diameter tube, which also pushes the TB further out.

[KRAM36]

Look at the Y on this baby. Figure out how to do this.



[IMG]http://www.****************************************************.com/mm5/graphics/00000001/991%20911%202014%202015%202013%20porsche%20carrera %20ipd%20plennum%20plenum%20performance%20air%20in take.jpg[/IMG]