3D printed 2.3T SVO intake manifold

[yaboyhalle]

Since there's not more options coming out for intakes, especially for the later dual plug heads, i've decided to do it myself. This will be my second version that's more aligned with common turbo manifold design. Version one ran the early DP lower and was good enough to get my mustang back from overseas (military stuff) but eventually started to crack on the threads and leaking boost. I used PA6-GF nylon for the material and everything but the throttle body threads seem to still work fine. I did blow out the gasket to the lower manifold at the long/thin section. Cutting a gasket without the vacuum port cut out fixed that issue. I was not really happy with how uneven runner lengths were unequal on the OEM lower and airflow likely wasn't very even with my upper design. The later DP lower intake seems to be a better design and is more easily available than the turbo manifolds now.

I have yet to print my most revised version as i still need to check the fitment on the car. I'm still learning best CAD practice and am testing things like the captive Oring channel between the manifold and plenum. I haven't added the 3/8 and 1/2 NPT vacuum and PCV ports yet, but most other features seem ready for feedback. Once i can test it on a running car, i'll upload the files for others interested in trying it out as well.

I've definitely checked my math on design choices with what i could find online, limited mostly on packaging.
It's set up for a 75mm throttle for ease of connecting to intercooler tubing. Haven't decided on making a more compact, integrated throttle cable bracket or the throttle spacer like before.
countersunk bolt holes for part alignment.
uncrushed rivet nuts for throttle body mounting threads.
a bracket to mount the universal FPR to the intake to meet a class rule that i've since forgotten which and run the OEM returnless fuel rail.
upper+lower runner length is around 13.4 inches, 8.85 in the OEM lower and 4.55 in this plastic upper. I believe the early DP intake lengths were 12.4 on Cyl 1&4, 15.5 on cyl 2&3.
haven't decided on adding in Orings to the throttle body and lower ports yet, or run a gasket.
gasket matched holes to the lower at 45.75mm, leaving a bit of porting room in the lower, and 50.325mm with a short bellmouth in the plenum.
Should fit on printers more than 320mm x 320mm on the plate.

If there's any suggestions or questions that can improve the design for our engines, please let me know. There's plenty of time to work on it, so I'm happy to adjust. More than one perfectly flat flange isn't a 3d Printer's strong suit, but flat decking with sandpaper on glass or something should work well.

Early DP intake




Oring crush test



Flange/gasket fit test



Earlier revision, fully printed for fit test on car




CAD screenshot of what i'm working with atm

[99StreetRanger]

This looks killer

[ATPCR]

Good to see you working on a DP head 2.3 engine. That reminded me of an idea that I had to use a pcm from an 8-plug Crown Victoria and a modified harness to have it fire on 8 individual coils. Michael P would probably have to tune it and per cylinder make the paired plugs fire overlapped much like how an old dual point distributor would extend the fire time, spark duration. Also, the added benefit of the later model version of the A4LD. It's just an idea.

[yaboyhalle]

I believe you'd need to wire 2 coils to 1 trigger wire, but i could be wrong. if you wanted to, i bet you could get a 5r55e and a ~99ish ranger 2.3 ecm working as well.