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Old 08-15-2021, 10:34 AM   #1
tmp042
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Default Custom Turbo intake

I wasnít overly impressed with the fitment of the Silicon Turbo Intake produced by a well known manufacturer, and didnít like that it had to be stretched to fit the Blouch compressor housing (I know they are designed for OEM housings). They all need to be slightly deformed around the TGV, so early 2020 I decided to give it a crack at making my own.
I used nylon PA11 on a HP Multi Jet Fusion printer and did plenty of sample testing. It was incredible to see small samples of 0.5mm (.0196Ē) wall thickness take 150PSI of pressure while in a oven at 150 degree C (302 F). The 0.4mm samples only ruptured as I was intentionally pulsing the air pressure.
The most impressive part was the thermal properties, I could pick up the samples straight out of the oven, where as the pneumatic metal fittings attached to them most certainly required gloves. That was one reason why I wanted to avoid making another aluminium intake.

My main goal was to design the smoothest possible transition around the TGV, to achieve this I machined flush the compressor housing and tapped it to suit a flange mount. Probably fair to say its one of a kind. I relocated the breather fittings to suit my catch can location by the ABS module.















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Old 08-15-2021, 11:14 AM   #2
Killfire
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Amazing work! I can't tell but it's there any kind of seal on the compressor housing?
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Old 08-15-2021, 11:57 AM   #3
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Quote:
Originally Posted by Killfire View Post
Amazing work! I can't tell but it's there any kind of seal on the compressor housing?
Good catch. O-ring groove is what we've done in the past, but the plastic won't hold up, even with a thick flange. Unless you use a plastic v-band flange that's evenly loading the ring. 911s do it this way and it works very well with their plastic inlets.
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Old 08-16-2021, 04:31 AM   #4
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Originally Posted by Killfire View Post
Amazing work! I can't tell but it's there any kind of seal on the compressor housing?
Cheers.
There certainly is a gasket. Initially I planned to machine out an o-ring groove on the compressor housing but thought to try it with a laser cut silicon gasket. The rigidity of the nylon is impressive and even when heated I cant deform the flange with my hands.

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Old 08-16-2021, 07:15 AM   #5
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The rigidity of the nylon is impressive and even when heated I cant deform the flange with my hands.
It is, we do 3D printed prototype stuff all the time. They work well, but have their limitations with the most challenging one being longevity due to creep.

It's something that difficult to bench test, especially an application like this, but squeezing with your hand is not going to come anywhere near the point load of a bolt head.

I would recommend bolting the inlet to the flange and using feeler gauges to see how much it lifts between the bolts. Ease into it slowly making note of you the torque you are applying as you go around the bolt pattern. You will find when you hit a certain point, it will start to deform. That's the limit you do not want to pass in-use. In fact, you want to be below this point by a bit, or it will accelerate creep.

The trick with the silicone gasket is that it will have a large surface and be far more difficult to crush/seal vs an o-ring. It will deform between the bolts much more than with no gasket or an o-ring. A traditional o-ring will take a lot less force. Given that it's a fairly low vacuum application, I'd go that route.
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Old 12-23-2021, 04:41 PM   #6
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This is once again a reminder why we have to sometimes DIY.
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Old 12-23-2021, 04:42 PM   #7
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Originally Posted by tmp042 View Post
This is once again a reminder why we have to sometimes DIY.
https://youtu.be/GUOwePWr2gQ
Literally all that guy said in his video is it was tight and he had to slightly bend a fuel line.

Yawn. No **** it's tight.
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Old 12-23-2021, 07:28 PM   #8
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Originally Posted by K3rm1tth3fr0g View Post
Literally all that guy said in his video is it was tight and he had to slightly bend a fuel line.

Yawn. No **** it's tight.
Not only that, it's on an engine we never said we support, a chassis we never said we support, from a market we never said we support for this product.

Complaining it's tight is laughable, when it's never even been tried before
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Old 12-23-2021, 07:49 PM   #9
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Are the Bugeye 2.5L over there?
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Old 12-23-2021, 07:55 PM   #10
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Are the Bugeye 2.5L over there?
I do not think so.

Last edited by K3rm1tth3fr0g; 12-23-2021 at 08:01 PM.
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Old 12-23-2021, 08:58 PM   #11
seitanist666
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Originally Posted by K3rm1tth3fr0g View Post
I do not think so.
That's where any reasonable difference would be - if the US and AU bugeyes have different engines/manifolds. Over here 01-02 SF GT is the same as Bugeye, so seems a fair assumption that if a product says it'll fit an 02 WRX, it'll fit SF and Bugeye over here.

Re fuel lines - that wasn't a big deal to me, they'd likely been bent up from the mani sitting around. Point of the vid was more to draw attention to the fact that it's hard up against the mani in several spots, and that's before fully installing with coupler and lined up to the turbo etc

Not to detract from tmp's thread though! I've chucked the vid up in the car part reviews and 2L tech section for further discussion. I think it stands to reason you'll always get a better product with a tailored approach - trade off is not everyone has the time, skills and tech at their disposal to pull off what tmp's made!

Last edited by seitanist666; 12-23-2021 at 09:00 PM. Reason: Tiny typo
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Old 12-23-2021, 09:39 PM   #12
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so seems a fair assumption that if a product says it'll fit an 02 WRX, it'll fit SF and Bugeye over here.
That's a terrible assumption to make. We've had so many cars in our shop for product testing over the years. Many parts within a gen or over several gens are the same, but that's not always the case. Early GD bugeyes and later GD hawkeyes have differences. There are LOTS of GR variations from 08-14. The latest VA chassis: intercooler, PCV, fuel lines, etc... This is just on the STi, and you'll find the same thing across WRX, LGT, OXT & FXT. Not even getting into different market variations and RHD vs LHD.

There's no USDM models we would have test fit that, that would have been identical to your Version 6 JDM engine. We've done JDM engine swaps, and there are always parts that are different: fuel lines, injectors, PCV, TGVs....
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Old 12-24-2021, 04:57 AM   #13
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Noones talking about ver6 dude. I'm literally talking about Bugeye to Bugeye, from US to AU markets. Within different facelifts of GD chassis, yes, I'd expect there to be differences, but I'm sceptical of there being differences between markets unless one had gear on it from a newer facelift. Eg US Bugeye being equivalent to AU blobeye. Otherwise, I feel like it's a fair assumption that they'd be the same, and for the same parts, hence my video showing the fitment. All in all though, I'm not interested in arguing semantics, and would genuinely be interested in exploring any differences between the manifolds etc and compiling, as that too would be useful and relevant info
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Old 12-24-2021, 06:52 AM   #14
KillerBMotorsport
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Originally Posted by seitanist666 View Post
Noones talking about ver6 dude. I'm literally talking about Bugeye to Bugeye, from US to AU markets. Within different facelifts of GD chassis, yes, I'd expect there to be differences, but I'm sceptical of there being differences between markets unless one had gear on it from a newer facelift. Eg US Bugeye being equivalent to AU blobeye. Otherwise, I feel like it's a fair assumption that they'd be the same, and for the same parts, hence my video showing the fitment. All in all though, I'm not interested in arguing semantics, and would genuinely be interested in exploring any differences between the manifolds etc and compiling, as that too would be useful and relevant info
Your own words...

This engine is a JDM Ver6 STI motor with what I seem to remember being a bugeye intake manifold.

We've done several JDM swaps and there absolutely are difference. I've said it before, there are differences in PCV, fuel lines, among many other small things. On some gens there absolutely are difference in the intake manifolds as many other countries have different emissions requirements, and fuel variations vs the US. You can say these are semantics, but when you might have a TGV, or PCV hard line, or hard fuel line, that causes the inlet not to go into place without tweaking one or more things, it's not a semantic anymore.

Every car on our fitment list we've had here and installed. Early on we even removed a couple because the 'assumed' fitment was wrong. 06 STi is a perfect example. The inlet would slip right in on an 07, but the 06 fuel lines pushed the intake up enough that you had to take a wrench and tweak it a bit to get the inlet in place. Because of that necessary tweak (even though it was small and simple), we removed it from our fitment listing. If the inlet didn't go in without tweaking things, it did not go on our fitment list. We don't know what everyone's skill sets are and/or how comfortable they are making modifications to other components on the car, so we remove those from fitment. On top of that, with all the turbo EJ platforms out there (OXT, FXT, LGT) (USDM, EUDM, JDM, AUM), it would be a nightmare to make instructions for every little nuance in each MY.

We obviously want to know ALL the fitments out there, and I absolutely understand your frustration with the install. I'm not trying to take anything away from your feedback. I think it's fair, and I've said that publicly. I'm just trying to shed some light on our process for fitment and how we get to where we're at with it. We're a company that goes the extra step with our product development process, which I think many appreciate, but unfortunately for a lot of things, there just isn't a one size fits all.
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Old 12-24-2021, 08:32 AM   #15
snow_bound26
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Quote:
Originally Posted by seitanist666 View Post
Noones talking about ver6 dude. I'm literally talking about Bugeye to Bugeye, from US to AU markets. Within different facelifts of GD chassis, yes, I'd expect there to be differences, but I'm sceptical of there being differences between markets unless one had gear on it from a newer facelift. Eg US Bugeye being equivalent to AU blobeye. Otherwise, I feel like it's a fair assumption that they'd be the same, and for the same parts, hence my video showing the fitment. All in all though, I'm not interested in arguing semantics, and would genuinely be interested in exploring any differences between the manifolds etc and compiling, as that too would be useful and relevant info


I can attest to there being differences between the various markets. They are typically small and may not look like much until you're trying to fit US made parts in JDM or ADM parts on USDM, etc, etc. when I did a JDM SAVCS 205 swap into my first GD, the fuel lines were different enough that I had to take the IM off to install a silicone inlet even though the engine was out of the car. I can't comment on the v7 207 I have currently as that came with aftermarket fuel rails, but yes there are differences. Slight tweaks allow you to work around them but you shouldn't be surprised that due to various emissions and safety standards for different markets that there are differences.
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Old 01-04-2022, 05:37 PM   #16
seitanist666
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Quote:
Originally Posted by KillerBMotorsport View Post
Your own words...

This engine is a JDM Ver6 STI motor with what I seem to remember being a bugeye intake manifold.

We've done several JDM swaps and there absolutely are difference. I've said it before, there are differences in PCV, fuel lines, among many other small things. On some gens there absolutely are difference in the intake manifolds as many other countries have different emissions requirements, and fuel variations vs the US. You can say these are semantics, but when you might have a TGV, or PCV hard line, or hard fuel line, that causes the inlet not to go into place without tweaking one or more things, it's not a semantic anymore.
Lol don't think they are my words dude xD def not anything I've posted on here, notably cos it's irrelevant - part says it fits Bugeye, I've fitted it to a Bugeye manifold.

For a quick update, I've since fitted it to a bare manifold - just TGVs attached, and confirmed there's interference with the actual manifold and TGVs, it isn't caused by fuel lines or PCV lines etc that are easy to tweak. So seems if this fits a US Bugeye manifold flawlessly, the US Bugeye mani or TGVs or both have a different casting to AU/JDM. Would be cool to see em side by side, but I think that's as good as we're gonna get!

Last edited by seitanist666; 01-04-2022 at 05:39 PM. Reason: Editing out glitched emoji
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Old 01-11-2022, 11:34 AM   #17
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Perhaps it's time for you to start a new thread rather than hijacking this guy's cool home brew intake setup thread. to the original poster- that intake looks awesome. What a cool build- look forward to hearing how it holds up.
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Old 01-11-2022, 12:02 PM   #18
K3rm1tth3fr0g
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Perhaps it's time for you to start a new thread rather than hijacking this guy's cool home brew intake setup thread. to the original poster- that intake looks awesome. What a cool build- look forward to hearing how it holds up.

lol he already has like 3 of his own threads SMH
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Old 01-17-2022, 01:21 AM   #19
97 Pimpreza
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looking at the 2nd to last pic of the first post made me very uncomfortable before realizing it was on a lathe....
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Old 01-21-2022, 03:28 PM   #20
seitanist666
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Quote:
Originally Posted by GeoNV View Post
Perhaps it's time for you to start a new thread rather than hijacking this guy's cool home brew intake setup thread. to the original poster- that intake looks awesome. What a cool build- look forward to hearing how it holds up.
Lol yeah I tried to redirect discussion to one of the other threads a few posts back so as not to clog tmp's thread, but alas.

But yeah this custom intake is just the tip of the iceberg - tmp's done some really amazing custom work on his subie, all really high quality stuff. Once it's finally done it'll be too nice to drive haha
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