2zz engine/transaxle/supercharged k20 swap

[exigeme]

After a week of sweating and hours of fabrication / welding I have the start of a
intake manifold. I had been waiting on a nose drive to determine the exact
supercharger position but got tired of waiting on vendor A and found one
elsewhere and had it overnighted it to me last Friday. It is not the best looking
manifold but it will definitely flow and is very compact. There is more to be done
on it but at least you can see how it mounts and partially supports the supercharger.

[2-Y-CHROMOSOMES]

I will first give you some kudos on being inventive and going for it.....

now for the sarcasm....

[jim-clayton]

The intake looks real good. Nice support for the SC.

[xtn]

exigeme, you're getting me all hot and bothered...

[choi0706]

Originally Posted by xtn

exigeme, you're getting me all hot and bothered...

bothered?



Hrmm, I'm wondering what this might cost, pretty soon I'll be knee deep in k20s..

I'm loving the manifold..

[ZAMMY1]

IMPRESSIVE! AGAIN!
thanks for the pictures.
sam

[codymac]

Only trouble is, that manifold has a big hole in one end of it!

[exigeme]

I am not looking forward to making the transition from that odd shape to a 3.5 round to feed the inter-cooler. Working on trying to come up with some more support locations to hold the the supercharger rather than have the manifold do all of the work! Milling machine here I come!!!!

[MikeW]

I'll trade projects with you for a while. I'm tired concrete, angle iron and the over engineered 17' rolling gate I'm trying to finish in triple digit Phoenix weather.
I'll think of you when I walk by my own mill. PS. Your welds look better than mine, but I'm using a stick welder. Looks like you're doing a good job.

[exigeme]

Thanks Mike...I loved the comparison between stick and tig welds do they look that bad? Is that the same gate you were working on last fall? Ha Ha Chio, what costs were you asking about? The intake manifold or the complete swap? The intake is not very expensive in material costs but difficult to make because of all of the welding and time involved. Having never made an intake before and trying to incorporate some sort of support for the supercharger is very difficult due to the accuracy needed for the proper position of the supercharger and the pulley. With every weld the manifold changes shape slightly. If I had to due it over I would have used a thicker material on the underside of the supercharger and machined it after it was all welded. Live and learn..

[MikeW]

I understand. Everything I do seems to be a prototype. That's a good excuse anyway. Yes, I know metal moves all around when welding. Kinda leaves you wondering how things will look when done. As far as the intake bolts go, are there enough to deal with holding the blower also? I have a picture in my head that they look like the arrangement of the Toyota exhaust. Not far enough apart vertically. If not, I hope there's some unused or useable bosses or bolts somewhere in the vicinity of the new manifold to tie into. I'd probably be crazy enough to weld additional bosses onto the head (don't try it, could be done on a bare head that's removed from the block). See, this is why my projects don't get done.

On a serious note, what is your opinion of the Honda transaxle? Anything over the 2zz trans?

[exigeme]

Mike, I know that the ratios in the JDM style tranaxle are closer ratios than the Toyota, as far as reliability I would think they are stronger due to the fact that they are designed to support a more powerful motor. Judging by the spline count they look stronger. I have a pic of both of them earlier in this thread with a spline count. The intake manifold will not safely support the supercharger by itself so I will be making a nose drive support and a support on the inlet side for axial stresses. The intake will only support the supercharger from sliding left to right.

[kortik]

wow getting closer ah?

[holmz]

Originally Posted by exigeme

After a week of sweating and hours of fabrication / welding I have the start of a
intake manifold.

Exigeme,

Have a lot of resect for the effort so far and appreciate the post.
And don't want to see it all go down the $hit hole now.

IMO the workmanship looks good but the engineering is lacking:
This is obviously NOT going to work as expected, as the difference between a flute and a bassoon is size, and those runners into the engine look pretty short - like they are made for the high notes (15k RPM).
I would think they should be a lot longer for <=8kRPM - like 8-12" long not 2". 9k RPM is 150HZ (but only 75Hz as it's a 4 stroke).
All the induction and exhaust should be tuned for a specific range. Just cranking in more boost can get equal power - but then the there is all the heat in the intake with no charge cooler.
IMO - You would be much better off to purchase an intake with an intercooler and longer runners - or make another with the tubes doing a loop down and then back up to an open plenum.
(I don't make them or sell them - but have seen at least one good example)

[MikeW]

Hear that Dan? You're doing this all wrong. Gotta have that runner length for the Helmholz effect, even with a blower.

[holmz]

Originally Posted by MikeW

Hear that Dan? You're doing this all wrong. Gotta have that runner length for the Helmholz effect, even with a blower.

Right Mike !
As you must know the term "Running at FULL SONG" has it's roots in the Helmholtz resonance...
There ends the daily lesson in acoustics - advanced study is LTR.

[exigeme]

Holmz, maybe you are correct and it won't perform at all however more has been done in my design that will have a positive affect on how it will perform that you can see. It is inter-cooled but you can not see that as of yet because I have not built the transitions to plumb the inter-cooler or have the inter-cooler mounted.
This FI system is not the same as Jackson racings or Comptec and is built for a supercharger designed to operate more efficiently at higher boost levels than the Eaton style. I plan to post my end results so only time will tell. If it does not perform as I planed I will redesign the intake and try again. After all it is just R and D.

[Simon S]

Originally Posted by MikeW

On a serious note, what is your opinion of the Honda transaxle? Anything over the 2zz trans?

I can answer this one!

So far (in 300+ kit's and 20+ race cars) yet to break a gearbox, they seem very strong, and so long as you stick to decent oil etc, almost idiot proof....

[exigeme]

Thanks Simon, that is good to hear. Do you have any experience with the Toyota gearbox?

[Simon S]

Originally Posted by exigeme

Thanks Simon, that is good to hear. Do you have any experience with the Toyota gearbox?

Not really, nobody has used one yet in serious racing....(gearbox that is)