The Kimball Project

madjak · Postby **madjak** » Sat Sep 12, 2015 7:33 pm

If you send me a highres photo square on to the intake/head and some dimensions I can draw up the CAD for you.

I did a quick overlay of a googled FS intake over the top of the skunk2 and it would work ok. You'd need to figure out the injector ports and if the angle of the intake would clear the chassis and brake master.

Ice88 · Postby **Ice88** » Fri Sep 18, 2015 2:18 pm

Magpie wrote:Have you considered making a custom set of headers for a BP?

Initially when I was looking at doing a BP build I did yeah

I'm in the process of trying to acquire an application that will allow me to model flow. Just for funsies :lol:

madjak wrote:If you send me a highres photo square on to the intake/head and some dimensions I can draw up the CAD for you.

I did a quick overlay of a googled FS intake over the top of the skunk2 and it would work ok. You'd need to figure out the injector ports and if the angle of the intake would clear the chassis and brake master.

Took a look based off your comments. Looks flipping close, shall see

madjak · Postby **madjak** » Fri Sep 18, 2015 2:27 pm

thinking about it some more, the issue I had with angle was mostly because the BP Intake ports slope backwards so it angles the intake down 10 degrees. I had to reverse this angle and add a little more for the throttle body to clear (total of about -15deg on the flange to the runners). With the FS head the ports look vertical, so you might not have the same issues.

The only hole that I think will be an issue is the bottom center one... but you could probably make a clamp bar that bolts either side. Might not be ideal but I'm sure you could get it to work.

colster3 · Postby **colster3** » Sun Sep 20, 2015 9:14 pm

I'm going to watch this thread

I like the ITB route (although I am more partial to the Honda intake atm) but both have a perceived brake clearance issue. I have wondered why nobody has thought about an aftermarket pedal box, moving the clutch and brake m/cylinders inside the car. Maybe it's because I am over 55 that I can remember Escort twin cams... Same problem and the Ford guys used this solution... :mrgreen:

Magpie · Postby **Magpie** » Sun Sep 20, 2015 9:43 pm

Pedal box has potential issues with road registration compliance as well as class issues. Looked into all that when I did my ITB build.

Ice88 · Postby **Ice88** » Wed Sep 23, 2015 12:57 pm

colster3 wrote:I'm going to watch this thread

I like the ITB route (although I am more partial to the Honda intake atm) but both have a perceived brake clearance issue. I have wondered why nobody has thought about an aftermarket pedal box, moving the clutch and brake m/cylinders inside the car. Maybe it's because I am over 55 that I can remember Escort twin cams... Same problem and the Ford guys used this solution...

Yeah i like that route as well. But its an expensive route

Magpie wrote:Pedal box has potential issues with road registration compliance as well as class issues. Looked into all that when I did my ITB build.

Bingo. I also can't be bothered going to that extent, I'd rather reduce runner length and aim for a different weaker reflection.

Ice88 · Postby **Ice88** » Wed Sep 23, 2015 1:17 pm

I'm a little saddened at the rate of progress at the fabricators, but its coming along. Here are some photos from a week ago that I've finally uploaded.

Engine in the car, oil pan girdle off. Shows plenty of room in comparison to an FE around the subframe:

More in focus shot:

Still a bit of room between the valve cover and the bonnet which is nice too:

Photo showing the angle of the ports and what straight shot from number 4 is like:

In other news I found my charger finally for my DLSR so can start taking photos in something other then phone quality which is nice.

Ice88 · Postby **Ice88** » Wed Sep 30, 2015 4:51 pm

My intake manifold and throttle body finally arrived, here are some shots of the manifold from yesterday. The manifold is a Skunk2 Ultra Street.

This is what the fs gasket looks like overlayed on the manifold:

Notice how much bigger the B18 ports are? No wonder the feckers make so much hp n/a.

Shot showing what the spacing and bolt hole patterns are like:

Heres what it looks like mounted in the car:

And this is where it all kinda goes sideways rather quickly, notice how high the manifold sits in the bay? due to the massive angle on the intake ports the B18 manifold sits so high that the front fouls on the bonnet.

At first I thought that it'd be an easy fix, machine the flange flat as the flange has extra angle applied. But yeah no, that won't work either.

Shots from some other angles:

Managed to cycle camera battery a few times in the charger, so that now works, yay! The throttle body just arrived this morning so will take some happy snaps tonight maybe after i get home from helping cookie.

madjak · Postby **madjak** » Wed Sep 30, 2015 5:29 pm

I think you have a couple of options...

Cut the flange and injector ports off the F intake manifold and graft it onto the Honda Intake. You'd need to make sure the angles and spacing of the runners 50mm or so up from the flange still match. It doesn't look as nice though.

kind of like this:

Or do what I did and basically chop off the flange at an angle (lose some meat off the bottom) and then weld on a new flange. The only issue there would be re-boring the injector ports. This also means that you can match your head porting with the new flange and then smooth it out to the runners where it is welded. If you do this, make sure you add bracing at the base as there is a lot of cantilevered weight hanging off the welds.

Will the injector angle of the Honda intake clear the rest of the head?

Other than the angle, it looks like it will fit just as well as mine. They are a nice manifold!

madjak · Postby **madjak** » Wed Sep 30, 2015 5:37 pm

3rd option is to make a wedge piece that bolts in-between the head and in the intake. Say a 10-15 degree wedge. Hard part here is you have to machine an angled flat or a tapered washer on the back side of the intake manifold flange to match the change in angle so that the bolt head sits flat.

Ice88 · Postby **Ice88** » Thu Oct 29, 2015 2:42 pm

So still not sure what I will end up doing regarding the B18 intake. The head port having such built in angle is a PITA. Building in a wedge is potentially the easiest versus chopping and adding in angle to the runners, but it adds length to the runner and its pretty bleeding tight already.

So not sure. :cry:

In the mean time there has been great progress on my mx5. Firstly some sexy headers:

Chopped and welded water pipe to alter the direction the water exist:

Custom Sump:

Ice88 · Postby **Ice88** » Tue Nov 17, 2015 3:36 pm

Some more pictures of the header, excuse the phone pics:

He also made a 2.5" Stainless steal exhaust which runs to the diff and then a 2.25" from the diff to help keep noise down:

Picked the car up on Sunday as well:

Apart from a chip on the drivers side rear and a few scratches no worse for ware form its 4 month stay.

Ice88 · Postby **Ice88** » Mon Nov 23, 2015 11:34 am

Thinking about running an Oil Accumulator as my sump capacity has decreased a bit. *sigh* Anyone have any experience or recommendations?

Also any recommendations on radiators? After receiving a warning about the ASI radiators leaking from the seller, I need an alternative. (Thread here:
viewtopic.php?f=29&t=70270)

madjak · Postby **madjak** » Mon Nov 23, 2015 12:49 pm

Those headers look great... such large primaries. Can't wait to see the powerband for this setup.

Is this car for street or only track work? I find on my car, if you're running an oil cooler then there isn't much need for a massive radiator when its N/A. My car runs cool with the little Honda one but I don't sit idling in traffic.

You could still get an ASI, just see if it can be discounted a bit... and if it leaks get it welded up. All the other radiators around tend to be in the $400-500 range.