Making of a liq./air intercooled turbo plenum

[j.oe]

I'm doing three GT3071 .78A/R twin scroll right now. For all those we want to install a plenum with l/a intercooler. For the first one i modded an existing mcx plenum, but that means 400€ for the mcx plenum and much effort to me to modify it. So i decided on constructing everything by my own starting out with a 0.12" aluminium plate and 80 mm and smaller massive aluminium shafts. First of all i constructed all parts in a 3D-CAD-system. Some more work, but its hard to construct measurements of angular arranged parts in 2D. Here for example the air intake flange:



Then i printed all masks for the single parts on paper and used them for cutting all parts out of the aluminium plate. The intake funnels i made on my lathe out of 80 mm massive round aluminium, the bushings for the injectors of 30 mm round aluminium:





First step of assembling is to weld the intake funells into the bottom plate. In order to an exactly positioned arrangement i made an iron bank to fix them while being tacked up. The injector bushings i welded up to a rectangular "u" aluminium 30x40 mm:







Now the bottom plate, side walls and top plate with injector housings are tacked up with the tig:



Then all other parts are tacked, the plenum comes out in its final shape:



All seams welded ready, there is a plenum ready for connecting it to the l/a intercooler core:



The core:



Next step was to weld up the air intake flange and weld plenum and flange to the core:







Last parts to be assembled are the water flanges:



And here it is, the finished l/a intercooled plenum:







.. and with my fuel rail:





For the next i will make the same plenum for upgrading my own busa from the mxc air/air intercooler to l/a intercooler. But here i even will construct the intercooler core by myself. I found some 3 ft long aluminium fin tubes with .8" overall outer diameter. 13 pieces, 10" long each, i will arrange to an intercooler core 10" x 4 1/2" x 3" between two flange plates.



... will keep you updatet
  Jürgen

[Mike-Nightrider]

I cant find the right words Jürgen.

Its AWESOME !!!!!!!

 
   

[SPEED KING]

Very nice ! !        

[Kojak]

Now we have more place to lower the front. Cant wait to make the fist drive -- 

[wornrear]

Wow, that is a work of art 


I wish I could weld......

[Coryonbusa]

Great work!

[Oz Booster]

   very nice, esp like the way you intergrate the injector wells and fuel rail.
and is that an air bleed i see on the top of the rhs water tank ?? 

[Nem]

Wow, that is a work of art 


I wish I could weld......

+1

[jgennaro]

Kick ass!

I get you can't wait to get it on and test it out!


Jason

[busa2001]

you got skills........

[atticdog]

Looks awesome Jurgen!!


and your getting really good welding aluminum

[murderedout07]

Awsome. How much, I want one.

[Stubbs]

Nice Work 

[j.oe]

  very nice, esp like the way you intergrate the injector wells and fuel rail.
and is that an air bleed i see on the top of the rhs water tank ?? 

Yep, that's an M5 tapped hole for deareation. When the plenum is installed, it's located to the very top of the water system.
To say the truth, the idea of integrating the injectors is copied from the mcx plenum i had modded the first time. But why should the wheel be reinvented 

[Scary-Jerry]

Very very nice Jürgen!  

I'll call ya...  
Jerry

[j.oe]

... and your getting really good welding aluminum

Well more plenums give more opportunities to practise  . Weld results are a matter of practise by 90% and only 10% of theoretics you have to know before getting started. Should have done more exercises on trash aluminium parts before i started with the first plenum shown in the GT3071R topic. The weld seams dont look that good there . But it was tight and will do it's job as well.

[Kojak]

Learning by Doing ..........................   

[dmbass]

Really nice job!

[balkanbusa1]

Nice Juergen! Really nice!