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DIY Budget Manifold Madness

5.3K views 14 replies 6 participants last post by  ImprezaRSC  
#1 · (Edited)
I've been stashing this for a while but it's almost done. This DIY intake manifold is part of my supercharger project but was a project in itself. There's a lot of little stuff going into it worthy of notes.

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The factory manifold is polished as are the steel fuel rails. It was fun going over little stuff and not spending a whole lot of money. The trade off is labor intensity. The manifold will still look like a "budget" piece when done but with some prettier peripherals and attention to details. There's about $400 worth of parts and work in the manifold with the Paxton, 440 injectors, and modded stock fuel rails. Emphasis is still mostly on functionality.

The WRX fuel injectors don't reach all the way down into the manifold pockets. I'll be trimming that material back inside the ports to unshroud the fuel injectors. That's the only horsepower mod that it will really have for port modifications.

I'll be using the parallel fuel rail mod and 440 injectors for some mild supercharged boost and E85. The fuel regulator in the picture is a Paxton adjustable unit to mount on firewall. There is enough fuel and flow on tap for 350hp+. I used slightly larger 5/16 fittings and trusty NAPA multi-fuel compatible line...6 feet of it. Braided line will come later as money allows.

All of this warranted using a spare intake manifold. Polishing it for appearances was bonus work to go with all the other work :crazy:. The new intercooler, piping, and brackets will be polished, too. The twin-screw supercharger is brushed aluminum. Anodizing and higher budget stuff was out of the question. Polishing is some labor but probably what a dedicated home enthusiast would do with their tools.
 
#3 ·
Sorry for the grainy pictures but a Flip Mino doesn't do well up close. I may have had too much artificial light.

I blended the hard edged stock injector pocket to unshroud the WRX injector's tip and spray pattern. The 440 injector tip sits deeper in the stock '00 RS manifold. It promotes a "cloud" spray pattern as opposed to a split spray pattern. The stock dual spray pattern 280cc injector fits flush in the manifold pocket to the port. The idea is to promote better fuel atomization and fix a potential flaw from using a shorter injector tip that isn't flush with the port. The stock WRX injector is flush in the stock WRX port. The stock RS injector also fits flush. The WRX unit isn't flush to the 2.5RS port.

Stock 2.5rs manifold pocket with a WRX 440cc injector installed.

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Blended manifold pocket

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Again, sorry for the grainy pics. 15 minutes of attention to each port with a Dremel I think was well spent.

Next will be the tapped fuel rail and parallel fuel rail mods.
 
#5 · (Edited)
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Here's what the inlet routing for the hoses roughly resembles. I have to do some further trimming of the steel tubing that was cut away. The length of the fuel hose doesn't matter as much as the equalized fuel flow to each bank. The inlet for the fuel basically tee's off of the fuel filter to both inlets on the driver side. The return lines travel out the back of the manifold to the regulator and into a single return line. This can upgrade later to twin Walbros and still handle plenty of flow. The restrictions would be if I used simple 1/4in. fittings. Inside, they're smaller than that! It's the little things like slightly larger fitting I.D.s and fuel lines that were taken care of along the way.

What's left is tapping the passenger side fuel rail with a steel bung for an AN fitting. After that it's the tiny stuff like clamps. It's nothing I spent recently, but you could still say this is about $400 worth of parts and labor including the manifold, WRX injectors, rails, accessories, and labor. That will be different for everyone. This is still entirely stock and replacement parts considering the manifold and parts used.

I used stock parts because they WERE cheap. :unamused: The rest of the polished stuff is a little pricey, but worth it. The irony to all of it is still using OEM quality pieces in one form or another throughout the build.
 
#8 ·
Well, it was a budget manifold if done in a few steps, but if counting the injectors and FPR, it pushes the $500 budget over by a fair margin...

Figure I'd leave just 1 picture to show the thermal wrap. Its inexpensive to buy and takes some time to use. Combined with a pair of thermal intake manifold spacers the gains are notable.



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#12 · (Edited)
DEI makes a varient of the thermal tape, but I purchased mine here:

<<PegasusRacing>> (that is a link to the actual page)


It goes on easily w/o heat, but has some trouble conforming to tight areas as it has a fiber strand backing. The adhesive is holding up really well and I've got no complaints about the product so far.

The injectors are Bosch 1000cc (from Injector Dynamics) and I've bumped the fuel pressure up to 55psi at idle. The fittings are AN-6 (3/16") and I can upgrade the fitting at the Y block to the AN-8 when I decide to run ethanol. The fuel pressure regulator should do a dandy job of regulating 2 different lengths of hose to each rail as well.

I'm making an airbox that will be covered with the gold wrap. I am however using something different for the FMIC piping though.