Help needed with custom GZE pipework design!

[TERRA Operative]

Here's the story. As you probably know, the stock charge pipes on 4AGZE are notoriously restrictive, so I am designing a new set of larger, freer flowing set. I am just stuck on one bit.

In the images below, the red flange is what bolts to the side of the supercharger near the firewall with the orange pipe going up to the top mount intercooler. The green pipe is where the air bypass valve connects (equivalent to a blowoff valve if it were turbo).
What I need to do is connect it all together. A kind of plenum chamber of sorts that makes a smooth transition from the square shape of the flange to the round shape of the pipe.
The pipe is 2.5" stainless with a wall thickness of 1mm. The flange is 10mm thick stainless and the hole is wider but shorter than the pipe. The angle required to be made is 90deg.




Anyone got any ideas? It needs to be able to be relatively easily fabricated, and I don't really want to have to go to milling a billet block... I thought of using a few pieces to make a box type arrangement into the required shape and forming the ends to suit the holes it attaches to.

Please help. It's doing my head in.

Oh, is anyone interested in a pipe? Once I get it priced, it could work out cheaper to get a bunch made. My design is easily adapted for front mount coolers too, simply by rotating the direction of the orange pipe to point over the top of where the cam gears are, or whatever angle is needed.

[30psi 4agte]

Anyone got any ideas? It needs to be able to be relatively easily fabricated, and I don't really want to have to go to milling a billet block... I thought of using a few pieces to make a box type arrangement into the required shape and forming the ends to suit the holes it attaches to.

.

Oh, is anyone interested in a pipe? .

/\/\ You packin ?? /\/\ Most of SA would be keen.

On a serious note: Note sure what yor fab skills are like ? But id just do what you mentioned and make the box type adapter out of plate and the use a 90deg bend on the end of it

Fairly straight forward really..... no need to stess..

[TERRA Operative]

I'm just trying to figure out the simplest way to do it. I think the box is the best so far. Will update my design tomorrow.

[30psi 4agte]

Have you thought of modifying the STD alloy pipe ?? IE cutting it plating it and putting the 90deg bend on that ??
Then use a silicorn joiner to join it to the stainless pipe ?

[fixeruperer]

thats not the bad spot for gze, the main inlet feed in the gze intake manifold and the inlet flange that bolts to it is tiny, ive before cut and shut the flange and pipe and opened up the port on the inlet manfold (so much that i had to space the throttle body out(becuase that mounts the the back of the manifold)).

[TERRA Operative]

Yea, I'm getting to that.... Just starting with the bits that are easy to remove...
I'll eventually redesign the 3 main bits of the intake. (TB to SC, SC to IC, and inlet manifold)

I think I may have a workable prototype here, just have to work out how to build it......








Any ideas on how to build the blue and purple bits?

[30psi 4agte]

What program is that you are using for those designs ?? --- I like it

[TERRA Operative]

I'm using Rhinoceros 3D. My version is a little out of date, but it has most of the functions I need.
It's really easy to pickup and use, my brother taught himself how to use it with relative proficiency in a few days.

[TERRA Operative]

I have decided to go for a square shaped box, aides manufacture and it's in the direction of flow anyway so it shouldn't have much of an impact on flow rates. It's just the pink bit that I'm not sure about (story of my life...) how hard to make one of those shapes? I have access to a 30 ton press, could I press it from a flat sheet of stainless with the appropriate moulds?

[30psi 4agte]

You could build that shape from sections of plate ,welding it and then cut / grind the hole later.

Thats how id do it anyhow..

You could always do the mould but it would prob be more of a PITA than it worth.

[TERRA Operative]

Yea, the blue section will def be pieces welded together. If I can get a mould made (CNC?) for the pink bit though, I reckon it would be easier to press in the long run if I am making a decent batch. It would help guarantee accurate results and a smoother surface on the inside too. The less steps = less cost and stuffups.
My software can output the required files for CNC machining, so that aspect is made simpler as well.
Once the plate is pressed into shape, it would simply be a matter of trimming the edges square and using a hole saw in a bench drill to cut the hole out.

[feral4mr2]

i've made a pipe for my gze (side exit though), useing a 2.5" 90 degree bend that i cut right at the start of the bend, it then went over the flange i cut out nicely. welded on and i just need to do a little die grinding to clean up some of my weld mess! haha.. i didnt weld on a abv pipe as IMO it isnt needed. (the abv that is).

i'll see if i can find some pics, though the welding on this might shame me.

found these.



2.5" pipe to the inlet manifold (from i/c) is next.

[30psi 4agte]

If ya gonna make heaps then ok...mould it is.

[TERRA Operative]

feral4mr2, not bad. Do you have any pics of the inside of the flange?

[feral4mr2]

i can take one today when i am working in the shed, post tonight.