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Old 06-08-2021, 11:56 PM   #26
tmp042
Scooby Newbie
 
Member#: 524797
Join Date: Jun 2021
Location: Straya
Vehicle:
2010 XT Forester

Default Custom Turbo Intake

I recently received a flurry of messages from friends regarding the Killer B intake due to its similarities (APS first produced the custom metal intake back in the early 2000ís). Early 2020 I decided to design and make my own intake which provided the smoothest transition to the turbo inlet. I disliked the idea of using the Agency Power or APS silicone coupler as it didnít allow the best taper. So I machined off the face of the turbo and drilled/taped threads for a flush flange mount. Aluminium is a brilliant heat sink so I instantly ruled out using it. Nylon PA11 is incredibly strong and when printed on a Multi Jet Fusion printer and the results are almost injection molding quality (though frightfully more expensive). In my tests small pressure vessel samples of 0.5mm (0.0196) wall thickness were printed and heated to 150deg C (302F) in an oven with 150psi of pressure in them. None of the five samples ruptured. The .4mm thick samples only ruptured when I intentionally pulsed the air. With nylon you can pick it up with bare hands out of the oven. The metal pneumatic fittings on the end were untouchable due to it retaining the heat. We couldnít test further as the double heat shielding wasnít enough causing the plastic pneumatic lines to burst.
Mine fits without needing to have the indentation along the side but obviously designing a product to fit stock setups would need them.
Itís been years since I was on this forum so have to try and remember how to attach images.

https://www.instagram.com/p/CIy9j0vltA6/?utm_medium=copy_link

Great work there Killer B.
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Old 06-09-2021, 08:45 AM   #27
KillerBMotorsport
NASIOC Vendor
 
Member#: 198281
Join Date: Dec 2008
Chapter/Region: MAIC
Location: Virginia
Vehicle:
2005 WRX/STi
WRB of course

Default

Quote:
Originally Posted by tmp042 View Post
I recently received a flurry of messages from friends regarding the Killer B intake due to its similarities (APS first produced the custom metal intake back in the early 2000ís). Early 2020 I decided to design and make my own intake which provided the smoothest transition to the turbo inlet. I disliked the idea of using the Agency Power or APS silicone coupler as it didnít allow the best taper. So I machined off the face of the turbo and drilled/taped threads for a flush flange mount. Aluminium is a brilliant heat sink so I instantly ruled out using it. Nylon PA11 is incredibly strong and when printed on a Multi Jet Fusion printer and the results are almost injection molding quality (though frightfully more expensive). In my tests small pressure vessel samples of 0.5mm (0.0196) wall thickness were printed and heated to 150deg C (302F) in an oven with 150psi of pressure in them. None of the five samples ruptured. The .4mm thick samples only ruptured when I intentionally pulsed the air. With nylon you can pick it up with bare hands out of the oven. The metal pneumatic fittings on the end were untouchable due to it retaining the heat. We couldnít test further as the double heat shielding wasnít enough causing the plastic pneumatic lines to burst.
Mine fits without needing to have the indentation along the side but obviously designing a product to fit stock setups would need them.
Itís been years since I was on this forum so have to try and remember how to attach images.

https://www.instagram.com/p/CIy9j0vl...dium=copy_link

Great work there Killer B.
Out first batch of Alpha test units was printed; reinforced PA12. None had issues, but I would not use it as a long term solution. Our wall is a bit thinner at .15 and at high vacuum (beyond real-world) it deforms some. You can squeeze the deformity out on a Flow-Bench and watch the CFM change some. At temp, this would only be worse, but again, this was at higher vacuum levels. Aluminum does not deform at all (in comparison) and shows no variances in flow like the plastic.

Design wise, out unit has a much larger bend radius, which we found is really key to optimizing the airflow. The indent is required for some models; 2007 Forester XT for example, providing power steering pump clearance.

With the cast aluminum part being stronger, we also increase the bell opening some on the inlet side, picking up a few more CFM. Part-for-part, the aluminum version flows a bit better, but we saw no discernable difference on the dyno.
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Old 06-10-2021, 09:37 AM   #28
tmp042
Scooby Newbie
 
Member#: 524797
Join Date: Jun 2021
Location: Straya
Vehicle:
2010 XT Forester

Default Custom Intake

I noticed many silicon intakes on the market have to be deformed to fit around the TGV/Intake runner. It was tricky trying to get the smoothest curve around the runner and when using a silicon coupler it created further issues due to the thicker wall thickness and hose clamp over the main intake pipe causing a further offset. One idea I tried was a dual o-ring sleeve on the end of the intake pipe which simply slid over the turbo housing. But at the end the impractical flange was the winner (clearly not suitable for retail). It would be interesting to see an image of the Killer B intake installed in the vehicle such as this image below.
https://www.instagram.com/p/CGJBOAxpge6/?utm_medium=copy_link
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Old 06-10-2021, 12:47 PM   #29
KillerBMotorsport
NASIOC Vendor
 
Member#: 198281
Join Date: Dec 2008
Chapter/Region: MAIC
Location: Virginia
Vehicle:
2005 WRX/STi
WRB of course

Default

Quote:
Originally Posted by tmp042 View Post
I noticed many silicon intakes on the market have to be deformed to fit around the TGV/Intake runner. It was tricky trying to get the smoothest curve around the runner and when using a silicon coupler it created further issues due to the thicker wall thickness and hose clamp over the main intake pipe causing a further offset. One idea I tried was a dual o-ring sleeve on the end of the intake pipe which simply slid over the turbo housing. But at the end the impractical flange was the winner (clearly not suitable for retail). It would be interesting to see an image of the Killer B intake installed in the vehicle such as this image below.
You need to not think round, lol. Our inlet goes from round-to-triangular-to-square-to-round again. This gave maximum cross section just before the coupler. The larger the volume in this area, the better. It has more of an impact on the quality of the flow than the coupler shape. You can make the coupler pretty sharp before it has a decent negative impact. If you want to maximize flow potential, smooth out that 90į bend a lot more. Our bend radius is not on a flat and significantly larger than yours. Keep at it
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