[The Morkinator]

http://i58.photobucket.com/albums/g2.../finality3.jpg



My name is Mat Morkin and I manage my family businesses CNC operations. We make foundry tooling for Prototypes, Oil Field, Automotive and Harley Davidson aftermarket. We help small to fortune 500 companies bring their products to the market. I just updated to Autodesk 12 and I wanted to model something with a degree of difficulty, so I did a N54 intake manifold. I've had this project on my mind for about two years. I am not a vender so I don't know how much I can say about it other than the manifold details. It will be made of of aluminum (red is just better to see against the gray back ground), weigh about 15lbs, features a larger plenum for a better top end, tapered runners that act as a velocity stack for more toque, 1/8 to 3/16 wall thinness. The kit will come with a phenolic spacer for heat issues, and some type of gasket.

I did not include aux port injectors because it seems that the DI, although limited, can push a lot of hp. Also, I do not own a n54, and I need one to really do it right. I just purchased a new CNC machine, and adopted a baby so my resources are a little light right now, but I hope to get one soon.


Next week I will have a phenolic spacer cut to confirm the ports and bolt holes, after that I will have the first two runners 3d printed to confirm the fitment in reference with oil filter assembly and alternator, next will be a rapid prototype wrapped in fiberglass to be dyno'ed. Then I will make the foundry tooling, casting, machining, polishing and then road testing. Hopefully the N54 will finally have a proper manifold.

If someone in the Houston/Dallas/San Antonio area can get with me for some measurements I can make it worth their while. Email me at Matmorkin@gmail.com.

[benzy89]

Subscribed.... I would be very interested, except the part where I live in NJ is going to get in the way. There are a ton of 335 owners in TX, especially since COBB's HQ is there so you should have zero trouble finding someone. Good luck w/ the fabrication.

[allornothing]

Subscribed as well good luck looking forward to the final product.

[klipseracer]

We would love to have additional injectors. Either for additional fueling, methanol, nitrous or whatever else you could stuff in there.

[benzy89]

OP start small, once the structural integrity of the new manifold is there, then start tackling new projects like meth/NOS injection ports. This would be huge if you could get this to work for all the weekend warriors & power hungry N54 owners -- This combined with some other upgraded internals + upgraded turbos would make a great foundation to start running some very aggressive boost.

Projects like this is how a full motor upgrade for the N54 starts

[The Morkinator]

Originally Posted by klipseracer

We would love to have additional injectors. Either for additional fueling, methanol, nitrous or whatever else you could stuff in there.

The problem with injectors is wiring. I've been doing some research, but until I buy the car it is all theoretical. You have to pull the port injector signal from corresponding DI injector signal, but I have no idea if it is strong enough, where to pull it or how to tune it. I just build stuff. I am going to put a boss towards the TB flange for Water Meth. However, I have thought of putting a single STI fuel rail on the plenum that can kick in at set rpm/boost level. It would supply two port injectors with a continous flow. I've even thought about running a n2o wet shot without the n2o. That's why I just want to make a bolt on and grow from there.

[NiVeDh]

Very nice!

[CaliforniaBred]

This would be great for the N54 community. How long would a project of this magnitude take to complete? Makes me want to donate my car to the name of science while I am deployed haha.

[aflatau]

in.

[The Morkinator]

Originally Posted by CaliforniaBred

This would be great for the N54 community. How long would a project of this magnitude take to complete? Makes me want to donate my car to the name of science while I am deployed haha.

Thanks for your service bro, I'm shooting for the New Year. Honestly the hard work is pretty much done, when I get my CNC machine in the tooling will be easy to make. Keep your car, let a pretty girl borrow it while your gone

[FoShizzle]

I remember a (SoCal) forum member doing a custom manifold a few years back. I think he had problems with it. Anybody remember?? I'm sure this would be useful for the OP.

[cstavaru]

OP, nice work but I for one can't see anything wrong with the current intake manifold.

With so much knowledge of Autocad and machining that you have, you could design other parts that are really needed. Like...how about an exhaust manifold for a twin-scroll single turbo ? Or 2 exhaust manifolds for a twin-turbo upgrade ?

I would be really interested in a true twin-turbo upgrade (with larger turbine casings), in order to keep some of the low-end the N54 is known for.

[jayzF30]

What hp will this make over the stock unit?

[The Morkinator]

Originally Posted by jazze90

What hp will this make over the stock unit?

I have no idea, when I get the rapid prototype made I can wrap it in fiberglass and dyno it. In my opinion it is fundamentally sound, larger plenum, tapered runners. The only thing I wish I could have done was make the runners longer.

[Jonny550]

Hay my name is Jon, Ive been around for a while and i work in the scrap metal business.

If you ever accumulate any hi temp alloys in large amounts shoot me a PM. Our company specializes in high temp alloys and sludge's.


Otherwise great idea for upgrading the N54's manifold.

[The Morkinator]

Originally Posted by cstavaru

OP, nice work but I for one can't see anything wrong with the current intake manifold.

With so much knowledge of Autocad and machining that you have, you could design other parts that are really needed. Like...how about an exhaust manifold for a twin-scroll single turbo ? Or 2 exhaust manifolds for a twin-turbo upgrade ?

I would be really interested in a true twin-turbo upgrade (with larger turbine casings), in order to keep some of the low-end the N54 is known for.

I have spent a long time mulling over the stock piece, it has a few draw backs, it's plastic, which helps with heat soak, but bad for strength. The runners bottle neck before they get to the plenum, and you do not have the option to use a larger TB. You need a proper alum manifold, with a larger plenum to take advantage of that turbo upgrade.

In response to your other pont, send me send me some turbos, I'll see what I can come up with.

[benzy89]

Originally Posted by cstavaru

I would be really interested in a true twin-turbo upgrade (with larger turbine casings), in order to keep some of the low-end the N54 is known for.

Originally Posted by The Morkinator

In response to your other pont, send me send me some turbos, I'll see what I can come up with.

+1, this is what I'd spend my money on. Never had any interest in the single-turbo upgrade & a complete true twin upgrade would be EPIC

[Lulz_M3]

If you could fit velocity stacks inside the plenum i would be interested. To really prove that this manifold is of benefit, you need to come up with a working prototype and show indivual cylinder A/F ratio. One of the biggest concerns is equalization of airflow across all cylinders. Blindly creating a manifold that will only flow more air is half the battle.

[mrbillytalent]

[benzy89]

^^This would prob require an actual manifold to be fabricated & then flow bench tested. I'm all for computer models, but I would want to see if it actually works in the real world.

[Velocity26]

I am sure that we have some Houston people that would be happy to assist with your project, they will likely jump in today when they see this thread.

[Eric335]

OP this was very interesting.....


i love seeing the Autodesk Inventor models too