Z-Fever:Anatomy of a Custom Intake Manifold (VQ35)

[Z-Fever]

I am Doug from Z-Fever. We build custom cars and do a lot of custom fabrication. We are currently building a VQ35DE powered 280ZX (old school but cool). We had to make a custom upper intake manifold to get the OEM hood to fit without hitting the engine. So, I figured I would do a tutorial of what it takes to make a custom intake manifold from start to finish.
I hope you find it interesting and educational.
Enjoy....

We start by scanning the stock gaskets where the lower plenum meets the intake manifold and the throttle body gaskets. Once we do that we digitize them to work with our design software. The images look like this:
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/308857_10150449574063296_296402898295_10224726_607 039180_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/297676_10150449574338296_296402898295_10224735_174 2415680_n.jpg

Then we create those 2D image into 3D images:
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/297499_10150449574358296_296402898295_10224736_202 5737756_n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300956_10150449574383296_296402898295_10224737_174 5265987_n.jpg

Then from those images we create the program that will tell the machine how to cut the blocks of stainless into these shapes. This program details the speed the machine rotates each bit, what type of bit to use on each cut, in what order to make each cut, and more. The finished products look like this:
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/305310_10150449580028296_296402898295_10224817_145 8692271_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/320195_10150449580253296_296402898295_10224820_188 7987637_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/294217_10150449824443296_296402898295_10225966_181 0248725_n.jpg

From here we create the image of what we expect the finished part will look like. We take the finished 3D images and fuse them together into a complete image. We also rotate and measure as we go making each piece fit so that we can get to the bolts on the intake flange. We map out exactly where each mandrel bent 2" tube has to be welded to the flange so that the clearances are accurate. This is what that looks like:
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300482_10150449574148296_296402898295_10224728_179 8301176_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/317870_10150449574193296_296402898295_10224729_115 31488_n.jpg
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/302303_10150449574253296_296402898295_10224731_279 776852_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296830_10150449574293296_296402898295_10224732_139 0682492_n.jpg


Then we make the intake plenum side wall where the mandrel bent tubes meet the intake. We make this ONLY after determining where the holes need to go in order to be able to get to the mounting points of the lower flange:
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/298100_10150449810863296_296402898295_10225900_523 380883_n.jpg

Then we put all the pieces together and cut out the 15"x15" piece of 16 gauge stainless that the intake plenum will be made from, the 4"x7" pieces that the front and back plenum walls will be made from, and we start welding.

Here is a pic of all the pieces before welding:
http://hphotos-iad1.fbcdn.net/hphotos-ash4/320077_10150449820473296_296402898295_10225933_922 382772_n.jpg
Here are the (6) - 2" 90 degree mandrels:
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/293327_10150449811048296_296402898295_10225901_166 9237318_n.jpg
Here is the folded 15"x15" stainless section:
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300297_10150449820303296_296402898295_10225931_107 0491185_n.jpg

We start by welding the mandrels to the intake side wall (you will see that the folded intake section is attatched to this side wall at this point but only to keep the side wall from bending and contorting its shape while being welded on):
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/297793_10150449824273296_296402898295_10225964_170 4841180_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/316887_10150449828188296_296402898295_10225990_106 263390_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/314999_10150449840658296_296402898295_10226115_200 3427651_n.jpg

Then we weld the mandrels to the lower flange:
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/291890_10150449828373296_296402898295_10225991_158 0502682_n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/294452_10150449840423296_296402898295_10226113_859 164760_n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/311765_10150451048723296_296402898295_10232004_300 463685_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/293508_10150451049238296_296402898295_10232005_851 721564_n.jpg

Then we cut off the sections of the mandrels that are sticking through the side wall of the plenum:
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300515_10150451048313296_296402898295_10232002_142 4584838_n.jpg

Then we fit the rounded plenum section to fit the side wall. Making sure that the clearance to the valve cover is accurate and also making sure that we increase velocity of airflow away from the throttle so that the cylinders furthest from the entry point get an equal amount of air as the one's closest to the entry point:
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/294113_10150451213763296_296402898295_10232730_191 2249640_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/299563_10150451214323296_296402898295_10232737_104 0094233_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/315729_10150451214773296_296402898295_10232745_122 1104076_n.jpg

Then we weld the throttle body flange to the 3" stainless mandrel intake pipe:
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/299534_10150451254988296_296402898295_10232831_428 289906_n.jpg

Then we weld the 3" stainless mandrel pipe onto the intake plenum at the angle we need to make the clearance to the valve cover and the hood.... It looks a little something like this:
(BTW... you may notice the Z-Fever logo plate on the intake tube. We already made the cold air intake pipe with the air flow meter flange we made welded to it rather than using the stock black plastic air flow meter housing, looks a ton better in IMO)
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/315054_10150451255378296_296402898295_10232832_749 389113_n.jpg
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/315054_10150451255378296_296402898295_10232832_749 389113_n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/307881_10150451255878296_296402898295_10232833_150 3666145_n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/311333_10150451256393296_296402898295_10232834_208 049346_n.jpg
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/312964_10150451256833296_296402898295_10232836_154 8712887_n.jpg

This shot offers you a good look at the inside of the intake after it is all together.
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/314394_10150451257283296_296402898295_10232837_136 8094959_n.jpg

By tomorrow morning (maybe 30 mins after we open) we will have this all closed up and the engine will be running. We will post dyno #'s after we get them to see if we have any actual realized gains.

As always, I hope you appreciate our post.

[revcyanide]

looks a lot like a better made xcessive one, I am real excited to see actual gains!

[simmode1]

Lovely work! Is there any particular reason why you guys didn't go with a front mounted throttle body setup?

[atutt]

Hmmmmmmmm.... Is this piece backpurged? It's hard to tell but it doesn't look like it.

A lot of those welds look hotter than they should be. Could use a lot more practice to improve consistency.

[sexcii-zenki]

lol i want 1 but with the throttle pipe facing the right side...cant wait 2c the gains

[DreamDriveDrift]

How did you come up with the optimal design? In terms of runner length, runner diameter, shape of the collector, intake diameter, etc?

[s13dan]

First thing i noticed was how terrible the welds are on the intake piping.. Please tell me they are just being used for fitment, because the intake manifold looks amazing.

[conrad_s13.5]

This is awesome!!!!!!!!

need to add to the fab thread when/if it comes back....lol

[Highway Riding]

Kinetix look alike? I had one. Meh.. sounded nice! The cosworth's are nicer. Nice fab work tho..

[OBEEWON]

Good for biz!

[Bushido]

Bad ass.


Lol at the weld snobs... But this is zilvia right?

[NickZ32]

how bad did that flange warp?

[hOngsterr]

Saw your thread on the 240sx VQ35DE Turbo!

very nice work

[bardabe]

needs back purge lots of crystallization inside the plenum, why not make it aluminum?

[trainkiller]

finished product?

[codyace]

Could use a lot more practice to improve consistency. Good job.



Are you speaking from experience or just posting to up your post count?


Sure we could pick it apart, but it looks fine and will undoubtedly make some power. Splitting hairs is one thing, but only on the internet do so many experts exist. Sure it could be better, but if it's already better than 90% of the junk created, what's the point in getting hyper critical?

[trainkiller]

Could use a lot more practice to improve consistency. Good job.

http://www.primeaffiliate.com/track/images/20.creation.jpg

wait are you serious?

Just look at a couple of build threads. These welds are pretty damn good, compared to some of them.

[Def]

Welds look fine to me, but the back of them needed to be shielded (backpurged or solarflux).

The weld-els have got to be heavy as crap though...

[revcyanide]

what happened to posting the finished product yesterday! : P

[sexcii-zenki]

what happened to posting the finished product yesterday! : P


thats why i came for as well

[s13 @ fullboost]

look great can totally tell the quality is good and great craftsmanship

[tryangle]

got my ecu and harness from doug, great work and when the motor isnt having issues it runs strong as hell.

[R33E8]

Wow, how much does that weigh?? Why not use aluminium? I can only imagine it would be much faster and easier to machine and cut (and weld for me)...

[omgRWDgoodness!]

Lol at the weld snobs... But this is zilvia right?

Sure we could pick it apart, but it looks fine and will undoubtedly make some power. Splitting hairs is one thing, but only on the internet do so many experts exist. Sure it could be better, but if it's already better than 90% of the junk created, what's the point in getting hyper critical?

These are probably the same experts who call this piece of fucking shit "Hella nice welding":

http://i467.photobucket.com/albums/rr35/boostlab/DSC06730.jpg

[90white240]

O my what the f#$K is that^^^^^

[pacotaco345]

O my what the f#$K is that^^^^^

DON'T TALK ABOUT MY CUSTOM FRONT MOUNT TURBO MANIFOLD LIKE THAT!!! lol jk, whoever made that should have his fingers welded together...

[conrad_s13.5]

*sigh,.. leave it to zilvia

[sexcii-zenki]

mr. doug...

still waiting on the end results...thanx

[Z-Fever]

Here is the finished product installed along with video
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/300859_10150465201273296_296402898295_10327010_139 3293534_n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/313505_10150465202443296_296402898295_10327021_204 1414535_n.jpg
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/387849_10150465202678296_296402898295_10327024_147 8671905_n.jpg
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/297290_10150465203288296_296402898295_10327031_904 161081_n.jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/393099_10150465203948296_296402898295_10327040_876 469866_n.jpg

And video of it running:
Z-Fever built VQ35 280ZX custom intake running.MOV - YouTube (http://youtu.be/PkN_BFLdOE0)

[Z-Fever]

lol i want 1 but with the throttle pipe facing the right side...cant wait 2c the gains

We did that already on our VQ35 Twin Turbo Drift S14:

Here is the pic:
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200579_10150178598228296_296402898295_8248940_7054 778_n.jpg

[Corbic]

Nice! Great swap idea, the VQs really are cheap engines and great for what they are. What tuning software are you using that you showed in the video.

[Z-Fever]

We are using the Osiris ROM editor software from Up-Rev. Great tool for 03+ Nissan vehicles. We are Pro tuners for them and use it daily.

[kalypso123]

great motor, but like someone said earlier why don't more people fab the throttle body forward.

[sexcii-zenki]

We did that already on our VQ35 Twin Turbo Drift S14:

Here is the pic:
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200579_10150178598228296_296402898295_8248940_7054 778_n.jpg

yea i've seen it b4 on ur site...how much would it run me??? or with the throttle toward the front...thanx btw looks good

[Corbic]

great motor, but like someone said earlier why don't more people fab the throttle body forward.

I suspect it has to do with the maf sensor.

[fyneyoungstunna]

Thats pretty sexy.

So for us Z guys, could this be the answer to our hood clearance problems as well?

[sexcii-zenki]

so no price?

[sexcii-zenki]

updates? reply? anything?

[stuckonfresh]

Great work! ...and I was wondering the same thing about the throttle body position. Could it go on the front, or nah?

[GrimDrifter]

has anyone made one straight forward center like this option 350z? probably only for turbo applications though.
Import Cars featured - Option 2002 Nissan 350Z - Super Street Magazine (http://www.superstreetonline.com/featuredvehicles/130_0402_2002_nissan_350z_supercar/)

[Z-Fever]

It isnt that we can't put the throttle body up front, it's just that on most applications it just wont fit because of hood clearance.

[Z-Fever]

Great work! ...and I was wondering the same thing about the throttle body position. Could it go on the front, or nah?

Very sorry for the late reply everyone. I must have some of my settings wrong. We just never got an email about any responses to this post.
We could put the throttle body wherever you wanted it but putting it up front posses an issue with clearance.
Feel free to contact me over phone to discuss it at 813-877-7600

Doug