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tooter 2.7 intake manifold spacer...

Discussion in '4 Cylinder' started by tooter, Jul 11, 2013.

  1. tooter

    tooter [OP] play every day

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    Greg
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    2012, std cab, 5 lug, 2.7, 5 speed
    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    I'm getting the stuff together to make a manifold spacer for the little 2.7 workhorse, and this is the finished project... :)

    [​IMG]



    This manifold will be used as the model for reproducing the details...

    [​IMG]


    The spacer will be machined with the proper grooves to accept a stock Toyota O ring intake manifold-to-head gasket exactly like the one already on this manifold. This will make for a nice secure reliable air tight fit exactly as good as the manifold. In fact it will be better than the manifold as the two facing surfaces will both be machined aluminum.

    The 2.7 enjoys the distinct advantage of having plenty of side clearance so the spacer will be a full 1 inch thick. I'll be making just one prototype for dyno testing. That's why I did these recent baseline runs. So there will be an accurate comparison when I do the runs with the spacer.

    The manifold runners that curl around from the orange gasket to the white line where they enter the plenum are 17 inches long.

    [​IMG]


    So a one inch spacer will make them 6% longer which should slightly lower the torque curve. How much isn't yet known. The dyno results will tell the tale. This is why I made damn sure to have a torque curve that starts before 1,500rpm. ;)

    I already have some experience making and selling manifold flanges, adaptors, "build your own" manifold kits, as well as complete manifolds...

    [​IMG]

    This is a purely experimental one I'm working on right now...

    [​IMG]

    The experimental plenum is completely devoid of any flat reflective surfaces to reflect the pulses coming out of the mouths of the runners.


    [​IMG]

    The runners are in direct alignment with the throttle body bore.

    [​IMG]

    It's going to be fun to see how this experimental project goes. :)

    Only if the tooter 2.7 intake manifold spacer turns in some decent dyno gains will they be manufactured and offered for sale to anyone who's interested in buying them. If not, the prototype will just be an expensive paperweight! :laugh:

    And no preorders... Only when they are actually in stock and ready to ship will they be offered for sale. Jerking people around is not my style. ;)

    I'll keep everyone posted on the progress in this thread. I just talked with CNC guy about the job today, and he's going to have his machine down for required maintenance for a few weeks, but this project is first in line when it's back in action. :thumbsup:

    Greg :)
     
    Last edited: May 17, 2014
  2. Tacoyota

    Tacoyota senile member

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    4.56 gears, rear trutrac,DT header, 235/85r16 Duratracs, 2nd filter pulled, inter.wipers, Cruise control, Factory alum. whls/winter tires(2nd set), Afe pro Dry-S , Dumbo eared flaps cut down.
    subbed. Hope it works out well.
     
  3. Kilo Sierra

    Kilo Sierra Member

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    What he said...

    ks
     
  4. tooter

    tooter [OP] play every day

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    2012, std cab, 5 lug, 2.7, 5 speed
    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    There's only one way to find out... and that's to actually make one and dyno test it. :)



    I've been doing flanges for about a year now so I'm familiar with the required details. This one should go pretty easily. :thumbsup:

    (the CNC technician took this nicely composed picture...)

    [​IMG]

    Here's the CNC machine making flanges two at a time...

    http://www.youtube.com/watch?v=rh4Ho5tI8KA
     
    Last edited: Jul 11, 2013
  5. Kilo Sierra

    Kilo Sierra Member

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    If I understand correctly you are focusing on torque gains?

    ks
     
  6. tooter

    tooter [OP] play every day

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    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    Exactly. :)

    Only low end torque.
    Not high end horsepower.

    Longer runners should move the torque curve down in the rpm range. How much if at all, I'll find out soon. If the concept works, I'll JB Weld two together and find out what 2 inches of extra runner length does to the torque curve. The little 4 banger has lots of room on the side. ;)
     
  7. Kilo Sierra

    Kilo Sierra Member

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    I like it...

    Good project/well thought out.

    Hope your efforts are productive.


    ks
     
    Last edited: Jul 11, 2013
  8. tooter

    tooter [OP] play every day

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    2012, std cab, 5 lug, 2.7, 5 speed
    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    Thanks, Kilo... :)

    I have a real day job for money. This stuff is just a fun hobby, and is an idea which I find to be totally fascinating...

    MicroBusiness. :)

    This is where just one person comes up with a concept...

    ...and finds another micro businesses to turn the concept into a design...

    ...and then hires another micro business to test a prototype...

    ...and if its proven to be useful by another micro business testing it...

    ...then another micro business is employed to manufacture a finished product from the prototype...

    ...which is then marketed by just one person...

    ...me. :)

    Notice that the complete process pipeline from concept to finished product is totally controlled by just one person. This allows the clarity of vision to explore and to innovate. I highly recommend this, and think that everyone should have their own microbusiness to experience the personal satisfaction of exploring creating designing testing manufacturing and marketing...

    ... on a really tiny scale. :thumbsup:
     
    Last edited: Jul 12, 2013
  9. RSC17

    RSC17 Well-Known Member

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    Subbed
     
  10. Kilo Sierra

    Kilo Sierra Member

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    Even better.

    Quality control vs production convenience.

    Good luck.

    ks
     
  11. StevoNB

    StevoNB Well-Known Member

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    Nice work. Subbd for the dyno results.
     
  12. danteisme

    danteisme Well-Known Member

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    subbed for results too! good work!
     
  13. Mr. Pick

    Mr. Pick Well-Known Member

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    Looking forward to seeing what the spacer does. Is there any spare vertical room to experiment with throttle body spacers?
     
  14. tooter

    tooter [OP] play every day

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    2012, std cab, 5 lug, 2.7, 5 speed
    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    Just took a look under my hood. This pic is with the hood popped 1.5 inches at the front latch.

    [​IMG]

    That difference is decreased as you move to the back closer to the hinges, but even at that, it appears to have 2 inches of comfortable clearance.

    You'd have to deal with repositioning the stock intake as there is a big plastic box bolted onto the valve cover. I got the Injen intake because the only points of attachment are the throttle body and one rubber mounted bolt near the air filter end. It can easily be repositioned simply by bending the mounting bracket.

    A throttle body spacer does absolutely nothing to enhance torque as the runners remain totally unaffected. However, it does make the plenum's volume slightly larger but that's it. Lots of people sell them on ebay. ;)
     
    Last edited: Jul 12, 2013
  15. tooter

    tooter [OP] play every day

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    2012, std cab, 5 lug, 2.7, 5 speed
    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    When I had the throttle body off, I made some measurements for reference.

    Throttle body bore 61mm
    Throttle body stud spacing 65mm square

    With those two measurements you could cut out your own spacer from some soft aluminum stock.
     
  16. Mr. Pick

    Mr. Pick Well-Known Member

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    You think even a tapered or venturi style spacer would have no impact on lower rpm torque? I know when I was drag racing I could change my 60' times with various shaped carb spacers, but of course a carb is a little different situation than port FI.
     
  17. camojared

    camojared Well-Known Member

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    Cant wait to see if you get any gains, and then with a 2in spacer. The little 4 banger does have tons of room.
     
  18. tooter

    tooter [OP] play every day

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    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    Yes, it's a different game now...
    All the throttle body does is meter air so there's no advantage in spacers there. However, if a manifold will accept one, you can make a change with a larger throttle body. That only affects top end though.

    [​IMG]

    I did that on my Yaris because the manifold had a bore big enough to accept one. We can't do that on our Tacos because there aren't any high performance manifolds made for them.

    The most beneficial mod I can see to enhance low end torque is longer runners. My 1996 had really long runners...

    [​IMG]

    It even had 8 intake ports. I looked at our 2.7 just to see if the intakes were still split, and they aren't...

    [​IMG]

    If they were, I was going to design a splitter in the adaptor flange, but since the split doesn't happen until right at the valves, it'll simply be straight through with no alterations.

    The intake manifold on my Yaris has 21 inch long runners... and for a little economy engine it has lots of low end torque.

    [​IMG]

    So as I see it, since a plastic manifold does not lend to customization, at least there's plenty of room to lengthen the runners with a spacer. :thumbsup:
     
  19. Mr. Pick

    Mr. Pick Well-Known Member

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    Thanks, Greg, that's all very insightful information. And thanks for answering my questions. Good luck with getting the spacer ready, can't wait to see what it does.
     
  20. tooter

    tooter [OP] play every day

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    Built for maximum low end torque, tooter II.VII intake manifold spacer, LCE long tube header, Injen long tube intake, 2,900 rpm torque peak.
    You're welcome, Mr. Pick... :)

    A hobby is doing something in your spare time that you love to do... and I truly love doing this. It's no end of personal satisfaction to explore uncharted territory. :thumbsup:
     
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