well i figured id share this
since i swaped to fwd heads on the engine i had to use a fwd manifold.
now the only problem is the fwd manifolds wont clear a distibutor.
i was able to machine the back of the manifold for dizzy clearance but i didnt stop there,im on my way to machining out the whole middle of the manifold to build a custom sheet metal design.
started with this

and so far ended up with this









still lots of material to remove before im ready to start fabing runners and such.ill post more pics as progress continues

 

finally had some free tiem to work on this a lil more,ill be finished witht the milling away of the storck runners and the rest of the manifold this weekend.and then i start to build the runners and plenum

 

Looking good-that seems like it is taking a lot of time to do it the right way-i know this is just an opion, but would it be easier to just fab the complet manifold? Also do those frount weel drive heads flow better, or what benifit do they offer? I am asking as i have a v-6 project to do also

 

no its actually easier to machine a stock manifold down liek i am doing in my case,since i run a turbo charged engine i want a very short runner(about 4 inch long).it is possible to machine an entirely new manifold,but its very hard to do since the port and pushrod layout.the pushrods actually come threw the intake.not to mention the intake is also part of the cyl head/valve cover rail.
the aluminum head are a canted valve design,and flow 60+ cfm better then the iron heads,using the aluminum heads requires u use a fwd pistion,the fwd heads have a 25cc chamber.the iron heads have a 50cc chamber, using rwd pistions with a fwd head will get u a 14.3-1 compression ratio

 

wow, looking good. can't wait to see what the finished product looks like.

 

this may actually give u a better idea of why its easier to machine a stock manifold to work







the pushrods would actually come up threw the plates,u can sorta see were i scribed the lines out for them.
also u would have to clearnce out the top portion for the guide plates and rocker arms,i found a simpler way of doing it but stoped working on the plates once i started to machine away the stock manifold to use.
next time i goto work ill dig out the plates that i machined for the pushrods and guideplates/rockers and take some pics with them installed.

besides all of the above when welding it all together there would be some issues with it warping and possibly not sealing up correctly,which is greatly reduced using the stock manifold base and machining it the way i am doing

 

looks like a nifty new idea, i'm pretty interested. keep us updated on the progress.

 

What kind of a mill/equipment do you have access to? Not a bad job… looks like some of the stuff that I’ve done with a router and a lot of perseverance….

 

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I am a huge "no replacement for displacement" kind of guy however, I like your attitude towards the V6's. If you intend to use the aluminum heads and RWD pistons and you have a compression ratio of 14.3:1 Then on your turbo charged application it seems you will not be able to increase your PSI by very much. I would guess no more than 5? Unless of course you ran some race gas of some sort.

So what is your plan to tackle your high compression turbo charged motor?

My guess would be to give your heads a bowl job and raise the cc's some more so you can run some more PSI on those bad boys. or get some Dead soft copper sheets that are pretty thick and trace and cut your own head gaskets. Or a combo of the two. I would not trust just any head gasket on this project.

I am guessing you want to use the RWD pistons... what comp ratio you working with with those?
I am interested in what you have going on.

 

i work in a family owned racecar/fabrication/machine shop,so i have access to any machine/tools that u would normally find in such a shop.
im using custom fwd spec pistons(forged),the motor has an 8.8-1 cr.only reason i went custom is so i could get forged,only cast and hyper pistions are off the shelf items

 

and what is your projected psi with that setup?

 

im unsure right now,only cause i dont know how much power it will make per said boost level,this new motor should make the same numbers my other motor does at a lower boost level.but just do give u an idea i ran 18+psi on my old motor,though i saw lil gain over 18 psi,due to the turbo pretty much being maxed out at 18 psi so efficancy droped pretty fast above that.
this motor is getting twin T04E's instead of the single T04E i used to run.

btw ill have more pics tonight,i finished maching the manifold and have started to fab/weld on the new runners,so ill bring the manifold home with me and take some pics and post them up

 

twin turbo would be a much more efficient way to go. The beauty of twin turbos is that you can reduce turbo lag greatly by having two different size turbos that spool different at certain rpms. Thus, creating constant and quick boost when your engine demands it. If you have the dollar, some single snail turbos are more efficient than any twin setup, but the price is a bit out rageous.

 

and it starts to take some shape

 

lookin pretty good so far

 

Looks very good so far.

In the picture showing the big gap, are you planning on just welding up the gap and grinding it down? I know it is not a big dral as aluminum is so easy to work with. Was just curious.

 

Yea, I think that we’re all a little confused as to where this is ultimately going… I’m assuming that the injectors will still be underneath it, but I’m not sure that I’m seeing where the plenum is going.

Honestly, for boost I’m surprised that you’re creating runners at all.

 

i was shooting for a 4 inch runner,but that would mean moving the injector location.in the last pic i can see the shape of the runner,i didnt get a chance to weld on the other 2 walls of the runner before i took the pics.

if this wasnt a street car the runners would have been alot shorter,but i still need some sort of power down low,so i had to make a few comprimises.what u see is just the runner,ontop of all that i will put a small to mid size plenum.
i shoudl be able to get some more pics up tommorow with some finished runners

btw were u see that gap.it is just that,the runners dont go all the way out to the sides of the manifold,once i get new pics up u will be able to understand it a lil better

 

update ive been slow working on this but heres a lil more work done,u can see the runners starting to take shape

 

What is your plan for a plenum?

 

im just gonna put a mid sized box plenum ontop of it

 

What about the TB. You should fab up a twin 58 mm on it. Trace out a TB gasket and you are set.

 

im going with a larger single prolly a 80 or 90 mm ford style

 

Hmm, what are you planning to do about the TPS and IAC? With TPI TB I can see how you would modify it but not with ford style.

 

im not using the factory ecm/harness,im going with megasquirt so the tps/iac isnt an issue for me

 

TPS is usually just a question of putting the right plug on the harness and getting the pinout right to get the thing to plug in.

IAC… well most GM TB’s use bolt on IAC housings, so it’s easy enough to drill 2 holes in a plate and then bolt on the housing/assembly and run a “external” IAC. Or if you’re a lazy monkey with 4 left thumbs there’s a few companies that sell external IAC housings specifically for running ford TB’s with GM style or aftermarket ecms.