Custom ported and CNC throttle bodies, upper and lower manifolds by Synergy Composite
 

Update 6/28/13



Ok I did the swap last night. Just wanted to show more pics and info regarding the before and after of all the parts side by side.

First up the weight of the ported lower vs unported, 5.80lbs vs 6.04lbs. So clearly some weight loss of material.

Next, the openings at the bottom of the runners running in both directions, 1.53" vs 1.43" is where the bump is that the injector is slid into. Clearly with the bump gone its opened up quite a bit!! The other way it not as much opened at 1.99" vs 1.98".



http://i39.photobucket.com/albums/e1...psa70f195f.jpg

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Next, the openings at the top of the lower mani are 1.70" vs 1.70" and 1.53" vs 1.52". The reason the upper part didn't open that much (only 0.01") is because every part on the intake system starts smaller at the TB then gets bigger for the next item. This is because nissan wants the parts to never have to "hit a lip" with air flow. It's better for flow to go through a small space and open into a larger one, than flowing through a bigger opening then hit a lip of metal of the lower mani and cause a bunch of turbulence. So the lower mani's upper part wasn't touched much because the upper mani is what got ported to be port matched to the lower. And looking at the pics with upper mani's gasket system we couldn't port more of it or we'd of ported into the gasket space destroying the upper mani.

http://i39.photobucket.com/albums/e1...ps32f4ce7d.jpg

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Next, 1.86lbs vs 1.92lbs of each TB.

http://i39.photobucket.com/albums/e1...psa081bbef.jpg

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Next, upper mani's weight, 7.90lbs vs 7.16lbs. Now why is the ported mani heavier than the unported? Well the ported one is off a g37. They for some reason give it very long cylinders where the bolts go through adding mass and needing longer bolts. They also use brass vs what looks like titanium on my 13 mani!! All my silver looking threaded parts are rainbow colored like when titanium heats up.

http://i39.photobucket.com/albums/e1...ps013dcbb5.jpg

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Next, the upper mani runners going in both directions, 1.85" vs 1.82" and 1.56" vs 1.50". Now you'll ask yourself these numbers don't match the numbers above for where it bolts to the lower mani's openings. That's because I didn't measure the exact opening of each item. I stuck my calipers down inside so they laid flat on the parts surface and measured wherever the tips made contact. This just insured a proper measure of each item. The calipers tips are like a 0.5" long so its inside more but i looked and each part is flow matched 100%. You can also see some horrible lips on the unported mani that needed to go away.

http://i39.photobucket.com/albums/e1...psbab0aa9d.jpg

http://i39.photobucket.com/albums/e1...ps95fdd7cd.jpg

http://i39.photobucket.com/albums/e1...ps3f47b629.jpg


Last, the opening of the TB hole on the mani. 2.47" vs 2.46". Again, because of flow its the TB that got all the porting and not the item it sits on. The TB is 100% port matched now to the upper mani.


On a side note. One thing I hate is the oil in the system! I'm not even boosted and oil comes out of the gaskets of the lower mani to head and injector o-rings. Just nasty stuff. I need to have my catch can running to atmos.

http://i39.photobucket.com/albums/e1...ps3475cfc2.jpg

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Update 3/17/14. Update.

AZ is out. IPS Motorsports in columbus is in. I stopped in the shop and talked to the porter for awhile. His prices seem very low and we can undermine even Z1's manifold with what I believe can be a much better job!

Also I talked to the tuner. We will do everything for you guys! We will dyno my car as is. We will install the lower mani. We dyno again. Then we will tune it. Then we will install the upper mani. We will dyno with the stock tune. Then we will revert back to the lower mani tune and we will tune off that for both mani's. Then do all that with the TB's.

You will know what power you make with each item you buy and add on and you will know the before and after of everything without someone lying and changing dyno numbers. It will be legit, I'll make sure of it as I do all the motor work!

Stay tuned.



Update 3/1/14. I now have a spare mani and lower mani. What I think ill do is just port them for starters. See what the dyno says and then when I get some TB's I'll send those for porting.



Wanted to do another idea I had because I haven't seen it anywhere yet. DEpoint0.5 and I have been talking about porting these items. DE has some TB's ready to do and I just bought the lower intake runners off eBay. I'm waiting to pick up a stock g37 mani off a friend and get some TB's myself so I'm not without a car. The goal obviously is more power. The question is how much power vs what the cost of the porting we be.

Z1 is now porting a stock mani and it's running about $300 plus shipping. The results seem to be you get as much midrange as the motordyne m370 mani (minus 0-3TQ) but you don't lose top end power like you do with the m370. Seems the best of both worlds right?! Well all I've seen is Z1's dyno's with the m370 vs their modded stock mani so it will be interesting to compare the stock mani vs a modded stock mani with my own dyno testing (no cheating ;)). Then on top of that i will be adding ported TB's and the lower mani since its a crude cast piece that looks very rough to the finish.

Fingers crossed it all works out and its a nice boost for NA power. I'll report back with pics of IPS's work as it progresses.

PS, if it does work out I'll send all 4 of my items to be ported again by IPS and sell them to someone looking for the whole package so your car won't be down. Then you can send your OEM stuff to IPS and the gift keeps on giving.

That's a great idea! I want in on this if it all works out :)

Do you (or Z1 for that matter) have access to a flowbench? That will really help clarify what is and what isn't working.

I wish. Not sure about Z1.

Even without one, you can make some educated guesses based on shapes, and you can certainly smooth out rough spots or ridges from casting, etc.

Here you can even see the casting lips inside the runners. Very rough. They need to go away.

Subd. Good luck guys, hopefully u can squeeze out a few more more N/A ponies. :)


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what do you guys think IPS should do with the TB's? anyone have experience on another car? either port the front and back of the TB and give it a knife edge or bore the whole thing and give it a bigger butterfly plate?

subd!!....i cant wait for the results!!....im definitely in if it works!!

I can't wait to build a full out NA motor. The heads and high compression is where it's at.

building one of these scares me from all ive seen. to much for me to handle with the valves and such. i give props to anyone that builds one! bolt on's FTW haha.

Can they make the GTR manifold adapter. I got one just sitting here lol.

Doesn't gtm already have one made?

Update!

Yea. Just go ahead and get GTM out of your vocabulary. :tup:

They're working on it. :rolleyes:

So 3 years like all 370z parts? Love this car. :icon14:

before and after pics of ported mani would be cool!? ;p

Will do. From the z1 pics I saw it can only be better. Plus the review I just read, it's not looking good.

I think this will deff give extra power! I know the gtr guys ported and polished there stock manis and got great gains, yes I know two completely different cars but still think there is potential.

Also if I remember correctly Megan bored out his TBs and had a custom intake and saw gains.

was that before or after he did the HR head swap though?

As seen the manifold to intake runner line up is slightly off....others and myself have sanded down the manifold to meet the intake runner better....same goes for the TB to manifold, the plastic mold kinda protrudes a bit and can be sanded down also making a smooth inlet...

I have polished my intake runner...want to

in for more

http://my350z.com/forum/intake-exhau...-clean-up.html

I've been contemplating cleaning mine up while it's off for the injector swap.

If I remember correctly, JUN bored the whole throttle body and gave it a bigger butterfly plate as well.

IMO, bore as big as you can without sacrificing the structural integrity.

I didn't test a ported VHR intake manifold on the VVEL engine neither on the HR engine.

my last testing was in 2012 on the HR intake manifold (barely ported) on the VVEL engine and there was a lot of gain below 7000rpm and pretty much the same 7000 to 7500

then I did a separate test on the 2 different size of TB and there was also a good gain there ,, but wont do **** if you still have the OEM air box since you need a bigger MAF tube.

Most of that stuff is in the first few pages of my Journal

Right now the HR Intake manifold has been port matched with the lower intake manifold for over a year now. but I haven't done any true testing on the dyno but did seen in avg more air going in (Maf Voltage avg.) during street tuning


Im XChacalX that posted some picture on there ;)

I am thinking about doing this with my M370 but have no experience with it, although it doesn't look too difficult to do. What tools do you guys recommend using, dremel attachments, etc?

I basically copied Megan370z (thanks :tiphat:). I used an air dremel and various sized sanding wheels and stones to carefully (CAREFULLY!!!) remove the rough parts from molding process and open it up a little. Then I used various grits of sandpaper to finish everything, all the while maintaining the stock shape (just getting the sharp edges out and opening it up a tiny bit). I also matched the upper and lower manifolds with the dremel and sandpaper.

The HR upper manifold (or M370) is a mess inside. The molded halves weren't meeting up correctly inside the runners. Turbulence was almost certainly reduced after I smoothed everything out, but I have no dynos to prove anything.

One thing to look out for when installing just the upper manifold:
There is room for the upper manifold to move around in relation to the lower manifold due sloppy tolerances in the bolts and holes that line up the two manifolds. This could cause a less than optimal flow. So if you're anal about it like I am, your best bet is to remove the upper and lower manifolds and match them. Then make a note of how they need to be attached to avoid a kink in the flow. There is probably an ~2 mm movement possible between the upper an lower manifolds on my Z. It might not matter, but I feel better knowing that everything now functions like one continuous runner with no kinks or sharp angles.

I'd prefer that but I don't want to pay hundreds more.

Makes sense. What AZ should do it gasket match the items. That way you're way oversized on the parts so that 2mm wiggle room shouldn't matter.

Props again man! I too have been slacking and haven't tuned since added a few breather parts!

From way back in my Honda days, TBs were bored out as big as you could go at the inlet side, but still retained some taper to the outlet side to help with air velocity. A bigger plate was included as part of the work too.

Very interested to see how this project turns out. Thanks for giving it a shot.

So a lot of work needs to be done. You can see lips, edges, and gasket marks where a good 1/8" of porting can be done to gasket match. Over all I think a lot of flow can be increased here.

As for the work getting done I'm not sure its going to be AZ. I still cannot get a response from him. I have a call out to someone else. I'll report back with what cost might run.

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man wanna see some results so bad

AZ is MIA?

Very odd, since he pretty much lived here while he was trying to drum up business for his overflow tank.

Maxbore.com throttle body boring service and repair quoted me $99 per TB.

Can Extrudehone work with the composite upper manifold?

I've always heard "No" because the compounds used will just gall up the plastic.

Frankly I'm gonna send my spare plenum + 300 bucks to Z1 and call it a win, rather than spending a lot of time and money trying to do it cheaper.

I figure if I see obvious defects on the lower, I will take it somewhere local and get it matched to the plenum, that paired with the bored TBs should get me 10hp or so at least, then I'm officially "done" on N/A mods.

Is there enough room between the lower manifold and the head for a phenolic gasket? I haven't had one apart yet.

I'm sure you could accommodate it, especially if you remove the engine cover.

To what end tho?