| Vowing not to put the chipmunk weeny stock exhaust manifolds on either my black '90 or my sivler '91, I began designing a new manifold a year ago. I would have gladly purchased a pair for a grand, yet none such existed. The only justification for the expense was to consider the marketing potential. The "new" design, which greatly improved the internal capacity and flow characteristics, was a "good" thing, however to only a limited market by requiring welding to re-locate the rear 10mm stud. 2006: I have just completed my new "core" pattern, the hollow portion of the manifold....and just sent it to the pattern shop to be re-created in silica sand. Now I am nearing completion of the frabrication of the tooling to create the "outside" portion of the new design. The key to making this new design a "winner", is the re-clocking the turbo flange angles. This accomplishes several design objectives: *It creates more space to accomodate rear stock stud location; * This "space" provides better port "gating" to separate effects of exhaust vortices from adjacent ports; * Accomodates a huge "collector" area 3X the cross sectional area over stock; and * "Fixes" the tortured extreme angle to the turbo flange, making a straighter shot (15 degrees right and left sides) creating a clean, smooth radius to the turbine wheel...the only restriction you want in your exhaust system. Just a few notes: Keep in mind THIS IS ONLY THE "CORE" pattern. To vsualize the actual manifold dimension, add 1/4" and flanges to what you see.....don't forget. pic #1 Core pattern next to pencil d!@% stockers. Did someone say....."flow test"? pic #2 Note straight, clean radius....direct bolt-up. My black '90 will get the compressors facing down with i/c pipes re-routed under frame rails & behind struts....out of hot engine bay, away from hot manifolds and radiator tanks. Remember....you heard it from AAE first. pic #3 One of my 4 core mock-up fixtures. pic #4 Driver's side w/ intake plenum and ALL intake piping in place w/ compressor housing facing south....you can actually SEE the new ceramic manifolds and monster 28 series turbos. pic #5 Passenger side, compressor down. pics #6 and #7 Final fitment after 40 installs of my mock-up engine, making the turbos fit the engine AND the chasis. pic #8 Finshed "core" pattern cast in polyurethane, in process of being re-created in silica sand as part of a 3-part sand mold for the iron foundry next week in time for the Z1 convention (it'll be close). One final note: Some from this forum have been less than supportive, despite my efforts to do something no one had succeeded in at the time: creating a high performance cast iron exhaust manifold. By being a direct bolt-up design, none of my prior critics have justification for not recognizing a better alternative to the stock manifolds. Unfortunately, this newly-designed manifold makes all other cast manifold designs obsolete, including my first design. To be true to a good design, I can't be compromised as others who are married to a personality or an outdated paradigm. My focus has always been comitted to the best end result. For those who can't recognize the amount of effort and expense I've invested, piss on it....I'm doing what I need to do to move on with the confidence and conviction I've had in my own abilities since I began 13 months and $8000 ago. Today, a little wiser and smarter, after 2 months of retooling, I am pleased to introduce my latest work at [ http://w82.photobucket.com/widgets/dynamicflash.php?featuretype=bucketstamp&featurename=manifolddesign&pa=/j265/i-xclr8/ ]
Thanks for your interest,
Jon Abeler, Abeler Automotive Engineering (AAE) St. Paul,
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