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Old 01-10-2007, 09:42 PM   #1
wgknestrick
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Roller Barrel ITBS

Default Roller Barrel ITBs and Custom Intake Manifold Design












(Puts flame suit on in preparation to be ridiculed by people with just TBE on their cars to tell me I didn't do something right)

Please note, the turbo is only a model that I found and is much bigger (5.5" inlet) than what is being used on my car.

I'd really like to thank quadtard (Shyloh) for offering to help get this project done with his expert CNC machining skills. He is proof that there are still good people left in this country willing to help strangers.

I really won't explain too much here as most info can be found in this thread:
http://www.tristatetuners.com/forum/...ad.php?t=23730

Build is in progress, but certainly underway. I hope to be done before Summer.

Bill
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Old 01-10-2007, 09:48 PM   #2
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Awesome, just awesome. I look forward to being able to see some real fabrication, not just on the PC
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Old 01-10-2007, 09:53 PM   #3
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sick, looking forward to seeing it real
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Old 01-10-2007, 09:54 PM   #4
wgknestrick
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Thanks.

I bet most people don't even know exactly what they are looking at. Ever since I saw the JUN Hyper Lemon, I wanted one. Since JUN will not sell it to me, I must build it....well try to anyways....just the engine bay.

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Old 01-10-2007, 10:33 PM   #5
wrxfactor
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Hahaha I was just about to ask how you planned to cool the charge in each of the two intake plenums. What were your other cooling options besides taking air from the IC? I really don't know much about individual throttle bodies but if you could direct me to a good place to learn that would be great, google was kind of a bust.
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Old 01-10-2007, 10:37 PM   #6
wgknestrick
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Old 01-10-2007, 10:54 PM   #7
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If I were you, I'd contact Corky Bell. http://www.bellintercoolers.com/pages/contact.html

Corky personally helped my local buddy Kienan with his twin turbo WRX and I'm sure he'd be glad to help with your set-up.



While I'm not intercooler design guru, my mental flow bench isn't happy with the existing design and maybe Corky can prove or improve your design. And it would never hurt to have him at least put an eye on it as he is considered by many to be a God amongst men in the turbo/intercooler world.

Kudos to you and hope to see you on the boards more, we miss you buddy!
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Old 01-11-2007, 12:13 AM   #8
modaddict
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LOL!

i don't know what Im looking at, but it looks SICK! free bump for you!

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Old 01-11-2007, 12:20 AM   #9
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Why a barrel throttle over ITB's? I think I remember reading somewhere about the some disadvantages w/ tumble and throttle response..
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Old 01-11-2007, 01:19 AM   #10
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You might have some cooling issues with that IC design. With a regular input on one side and output on the other, it's getting the air to flow all the way across the entire width of the intercooler, giving it more time to cool down. While in your model, it's only traveling half the distance.

But if it's a quality intercooler this may not be an issue, or you could apply other cooling methods.

Or I could be retarded and everything I just said had no merit Looks friken cool tho!
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Old 01-14-2007, 10:08 PM   #11
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Looks nice.... And expensive too! But it defintely will be a unique setup.. that's for sure... Good luck with it
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Old 01-15-2007, 02:47 AM   #12
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solidworks + photo option? email corky bell.
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Old 01-15-2007, 01:21 PM   #13
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Seems like a Coates style setup. With their roller barrel "cams".
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Old 01-15-2007, 11:47 PM   #14
wgknestrick
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Quote:
Originally Posted by wcbjr View Post
Seems like a Coates style setup. With their roller barrel "cams".
Not at all. This is only an individual "throttle" body setup. There is a big difference between a barrel throttle and a cam/poppet valve/coates valves.

I start fabricating the manifolds this weekend, but I am still waiting on my velocity stacks.

Bill
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Old 01-16-2007, 08:43 AM   #15
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Pictures during fabrication would be nice. I'd like to see what goes into those roller barrel ITB's... how they seal on the housing, etc. Very cool project!
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Old 01-16-2007, 09:45 AM   #16
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Quote:
Originally Posted by wgknestrick View Post
Not at all. This is only an individual "throttle" body setup. There is a big difference between a barrel throttle and a cam/poppet valve/coates valves.

I start fabricating the manifolds this weekend, but I am still waiting on my velocity stacks.

Bill
Just reminded me of it, thats all. Any pics of an actual implementation of rollers?
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Old 01-16-2007, 10:06 AM   #17
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Wow looks like a great design, what are the dimensions of the core you are using?

I REALLY like where you are going with this,

Mike
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Old 01-16-2007, 11:11 AM   #18
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make this into a kit if it works ! looks ****ing sweet, and props for actually trying and making it
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Old 01-16-2007, 01:01 PM   #19
wgknestrick
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Quote:
Originally Posted by vtecTHIS View Post
make this into a kit if it works ! looks ****ing sweet, and props for actually trying and making it
This has gone through my mind once or twice.

If anyone is seriously interested in doing this (and has CNC hookups), I have full drawings for every part seen. Radiator has also been taken care of, but not shown here (I'm being a little secretive on somethings until I decide whether to offer this) . I am probably going to do a full detailed walk thru (very similar to my Official Reversed Manifold thread) on how to do this.

For reference $, I have about $1K in machinist labor alone on the ITBs, and this is getting a couple of freebies. $550 for the intercooler from China Ebay supplier.

I'm not sure but could probably offer this as a kit in the neighborhood of the $3K range, but will see how easily it goes together and works.

This would hinge on being able to get components sourced from China, quality, and demand. The IC I got was of great quality and was cheaper than what I could buy the raw cores for by myself.

This would include:
Roller Barrel ITBs
DBW Synchronizer (not shown-uses modified stock TB housing)
2 Intake Manifolds
1 Intercooler
IC Piping
Vacuum routing and connections
Front mount radiator and hoses.

I've also thought of "bartering" the design for some tuning with some key people.

Bill
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Old 02-02-2007, 11:20 PM   #20
wgknestrick
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Some pics before stuff goes out for some more TIG welding. Manifold fabrication is complete. I just hope that the passenger plenum clears the hood when it comes back from welding. It is very close.



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Old 02-02-2007, 11:20 PM   #21
wgknestrick
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Old 02-02-2007, 11:29 PM   #22
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Reminds me of this pic from the APS website. They have it listed as "DR725 system shown with prototype intake manifold"




Though it doesn't look like they are using ITB and look to have much smaller plenums.
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Old 02-02-2007, 11:47 PM   #23
wgknestrick
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They probably have ITBs on that engine (I don't see a TB unless it is the round black silicone coupler looking thing at the plenum merge pipe. ).

Their plenums look to be 3" OD, while mine is 4". I don't know how they clear the hood with those big, tall bends / runners. Probably why it is just "prototype" and we've never seen in on a car.
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Old 02-03-2007, 12:02 AM   #24
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Old 02-03-2007, 11:54 AM   #25
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Looking great so far... can we get some pictures of the roller barrel housings? Or is what you have in there just spacers?
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