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My Motorsports adventure....

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GrindCustoms:
Good morning y'all!

Some of you guys seemed to have a bit of interest in what i'm working on in the engine/performance departement...

I'm a petrol head since... ...forever! So it felt natural to me to use my creativity/pseudo-engineering abilities for stuff in that domain.

What i'm currently working on is a new Intake Manifold setup for the Nissan VQ35HR & VQ37VHR engines, those engines can be found in Nissan 350Z - 370Z and Infiniti G35 - G37. These engines due to the way that their cylinder head are designed with variable intake camshaft lift and duration are very receptive to "breather mods" when in a Normally Aspirated (non turbo or supercharged) and LOTS of power gains can be found... ...they are there, just hiding... 
The gains are not like what you'd find on let say.... a Honda Civic after installing a Cold Air Intake... and it just becomes a raspy annoying thing...

Allright, meat and potatoes now! My first project is a conversion to use 75mm Throttle Bodies instead of the stock 60mm TBs. To acheive that, an adapter plate was required to accomodate the different "bolt pattern" of the larger TBs and also try to limit the "bottle neck" effect in air flow because of the limitations/tolerances that have to be dealt with the stock intake manifold...

The stock opening on the intake manifold is 61mm, i was able to bore that up to 67mm without compromising the structural integrity of the manifold. With that in mind, to minimize the bottle neck effect mentionned earlier, when having a reducer you don't want it to be a "generic taper" as the more you "vaccum" air in the manifold it becomes counter productive. You instead want a "volute" shape, also known as a Velocity Stack in the petrol head slang.

Here's the final version of the adapter plate that i designed, it took me 3 prototype to end with this one and couple Dyno runs to test the setup, this was made with a buddy that lives in Montreal and have a tuning shop, so i did'nt have to take an 8 hour trip to test out everytime.







In order to get these properly installed and optimise the setup, some work had to be done to the manifold so it accept the adapter, machining, porting and polishing is made in the first stage, as you can see here (stock on the left, modded on the right):



As i'm typing this, i'm now at the second stage of porting, the idea is to have a "seemless" joint between the adapter plate and manifold, as you can see in the picture, there's around 1mm of material remaining in the inner diameter, this have to be sanded and polished.



After this step, the adapter will be "molded in" the manifold and will be ready to receive it's new Throttle Bodies, here's a picture to show you the physical difference in size, there's 2 of these per manifold. (left stock, right 75mm)



The gains we produced using this setup have blown are mind, it's very rare that a "bolt on" solution will yeld that much increase in "wheel horse power"... the vehicule we used for our testing is a 2012 Infiniti G37Xs (AWD) Sedan with an automatic transmission, our baseline Dyno results, with stock intake manifold, throttle bodies and air intake was 256whp (keep in mind that AT transmission makes lots of parasitic loss and that the car is AWD and the fuse was pulled so it be RWD for the Dyno, hence even more power loss in the drivetrain as the transfer case robs some). Our end result with the new setup and 3" Cold Air Intake Setup (pictured below) was 307whp, that's a 51whp increase with a simple bolt on solution... ...and that was my motivation to push forward this DIY project of mine that i'm now working on getting a Patent and offer the setup in a commercial manner.





If this interest some of you guys, i'll post updates about it in this thread so you can see the results and build of this final version.

Cheers!

Rej

alanp:
Impressive 8) hope you make a few pennies off it!

GrindCustoms:

--- Quote from: alanp on February 16, 2018, 09:38:19 AM ---Impressive 8) hope you make a few pennies off it!

--- End quote ---

Thanks Alan!

Don't know if i'll make real money out of that but simply achieving new things is a reward by itself.

imjonwain:
I used to be into cars quite a bit (80's Rx7s) but mostly tinker on motorcycles in my spare time now (parts are so expensive :( ).  That's an insane HP gain for an NA bolt part/setup, I think that'll sell really well.  Does it sacrifice torque at all?  You need to an ECU/dynotune obviously right?  Are you doing it custom tune only or gonna do a loadable generic map for people? Are the bigger throttle bodies OEM for a different model?  I guess that's a lot of questions haha just curious

GrindCustoms:

--- Quote from: imjonwain on February 16, 2018, 12:41:14 PM ---I used to be into cars quite a bit (80's Rx7s) but mostly tinker on motorcycles in my spare time now (parts are so expensive :( ).  That's an insane HP gain for an NA bolt part/setup, I think that'll sell really well.  Does it sacrifice torque at all?  You need to an ECU/dynotune obviously right?  Are you doing it custom tune only or gonna do a loadable generic map for people? Are the bigger throttle bodies OEM for a different model?  I guess that's a lot of questions haha just curious

--- End quote ---

Rotaries, you're a masochist!  ;D

The prototype setup was'nt sacrifiying torque at all, in fact it increased it and brought it's peak torque 600RPM earlier and maintains it until the redline (7600RPM).
It asks for a complete new tune, with Nissan we use Osiris Uprev for the engine management, pretty neat and efficient software. The bigger TBs ask for a complete "re-scaling" of the MAF, even greater with the use of the 3"CAI. So yeah, Dyno tune is mandatory.
Those TBs comes from Nissan Maxima 3.5l wich uses a single of these. The stock setup uses "mirror" TBs wich means that one is wired NPN and the other PNP, so i had to get into the electrical aspect of the car aswell, to find the correct pinout so the TPS (Throttle Position Sensor) works properly, wich was probably the greatest challenge in this, since the improved setup uses two NPN throttle bodies.

There's another company in the market that offers a 70mm conversion kit, but they don't push the concept as far as i'm doing here. It's an adapter plate aswell but it keeps the stock intake manifold bore, my modification is a bit more intense but it also yells greater gains...

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