This is an interesting thread. Being that I have a non e-gas model the only way I can find to get a larger throttle body is the Pedro's bore service. His site says they bore the stock one out to 75mm. So if I do this I would be in the market for one that would fit that. Is that a possibility?

Non e-gas 3.4 911 throttle body.

Thanks edc, I was thinking this would work as well. But I was unable to find one online last night to be sure.

Size
 

Kram36....What size engine are you running?? 996 3.4 or 3.6?? and what size throttle body are you using?? Thanks....I too am waiting to see how Ben does !!

Yes I can do one for the 2.5 too, but since the 2.5's plenum is very different from the 2.7 and 3.2's plenum I will need to take the mesurement from a 2.5L one
:)

My friend told me Monday, I hope I will be able to do it and that all my measurement were right !

cross your finger with me ;)

Stock 3.2, 76mm TB.

Hi !

As planned I found a garage Monday to finally work on the intake !

and... it doesn't fit ... nothing bad, but the straight T shape makes the TB bump against the starter and force the intake elbow to stick too far up.

Nothing that a slight angle can't fix :)

I will make another one soon.

I also noticed that the temperature in the engine bay was higher than I thought on a hot Florida day !
So I put the T back into the oven to see if it can handle 240F ... result, it can :) I will just make it thicker in some place for added strengh and peace of mind !

It takes time, but I'm on the right way :)

Ben

I also think that I will try a flow divider like in the 987 :
http://986forum.com/forums/uploads01...1326572330.jpg
without the flap, but it's a great way to ensure that both sides receive the exact same amount of air despite having to make a tighter turn on the left side !

Curious why the air is making a tighter turn to the left side?

http://nsa34.casimages.com/img/2015/...5483936036.jpg

because I'm not going tu use a straight T shape any more, it will be tilted 10° :)

I will show you as soon as I'm done with the software.

The shape will look weird, but I'm trying to direct air equally on each side, not that easy ...

I'm going to try another route, like the oem (longer tube after the TB), and see if I can come up with a better, more balanced shape :)

also, the problem with a big divider is that it's going to "seal" the to banks from each other, and makes you loose top end power (sorry, I lack technical vocabulary to explain it correctly in english).


So ... I'm working on it :)

If anyone has any idea, feel free to share ;)

Ben

TRK (The Radium King) would probably be the one to consult on that.

Hi !

I made modifications to the T, with an angle, the TB should point slightly to the left.
this way it should clear the stater solenoid.

Now I need to see if the engine cover will clear the intake elbow.

I want to get it 100% right before printing it.

Remember, the short radius is what matters with any normally aspirated engine. I see people wasting their time with induction components, because they don't understand how dry flow really works.

Yep :)
But the space is tight, and the TB is really bigger than the 986 one, so I try to find the best shape with the room I have.

Hi !

I did have a lot of free time to work on the intake, but I think this time I'm good !
I realise that trying to make it simple in shape ... would making it harder to fit ...
So I copied the stock shape. It took me some time to get the angles as clos as possible to the stock T, but I think I'm close.

This way, It will clear the starter solenoid, and the engine cover :)

http://nsa38.casimages.com/img/2015/...4929423339.jpg
http://nsa37.casimages.com/img/2015/...4929741270.jpg

tell me what you think

Ben

T body
 

Great Ben!! When will you be able to make a few??
What material will you use (heat sensitivity)?

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

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..

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.
http://nsa38.casimages.com/img/2015/...1139386059.jpg

Ben

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 !

http://nsa38.casimages.com/img/2015/...0521844059.jpg

http://nsa37.casimages.com/img/2015/...0522878945.jpg

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


Ben

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

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

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

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 :)

Hi !
after months of designing and two weeks of waiting ...
here is the plenum :D
http://nsa38.casimages.com/img/2015/...2739279781.jpg
http://nsa37.casimages.com/img/2015/...2740272646.jpg
http://nsa37.casimages.com/img/2015/...2741278327.jpg
http://nsa37.casimages.com/img/2015/...2743282797.jpg

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

Looks very nice!!

So this is similar to what Pedro sells ??

thanks :)
Here's morehttp://nsa37.casimages.com/img/2015/...0725636616.jpg
http://nsa37.casimages.com/img/2015/...0724376260.jpg
http://nsa38.casimages.com/img/2015/...0725900204.jpg

As you can see, I quite nailed it :p
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 !

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 :)

Are you 3D printing these or 5 axis or ?

3D printing!

How much are they going to cost ?

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

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.

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

What size TB will you be using? Stock 996?

yep, stock 996 TB, way bigger than the stock 68mm.
The 83mm is a bit expensive for me ... but I will make the plenum for too

What is the size of the stock 996 TB?

74mm at the plate 76mm at the largest.
The stock TB fits inside the 996's !

WOW! We need more air. Will yours be a direct fit, basically plug and play with the 996TB? Add a 987 airbox and we are in business?