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New Air box

Discussion in 'S30 (240Z,260Z,280Z) Tuning & upgrades' started by atomman, Jun 4, 2019.

  1. atomman

    atomman
    Z Club Member

    After looking at the air box Rich brought and a few others have also got fitted , I thought I could do with one to,

    I did some measurements and did some quick CAD models and a few flow simulations, made a couple of tweaks and went about making a base plate and brought some foam to make a mould ,

    here's some photo's of the progress so far ,
    DSC_1664.JPG DSC_1910.JPG DSC_1950.JPG DSC_1919.JPG

    I did a bit of machining for a good friend a few weeks back , who make balsa long boards ,http://www.thewilliamslongboardingcompanyinc.co.uk/, so he is gonna finish off the plug/mould for me and then make the actual air box for me , i know my limits with epoxy,

    The plan is to use a high temp epoxy and a couple of layers of cloth and hopefully end up with a pretty clear air box so you can see the titanium trumpets through it , if this doesn't work we will already have the mould so can use carbon fibre cloth instead ,

    Hoping to get it done in the next few weeks so when i go to the dyno i can do some runs with and without the air box to see if there are any gains
     
  2. SacCyclone

    SacCyclone
    Z Club Member

    Having paid a lot of money for the T3 velocity stacks, i love the idea of a semi clear air box to show off the stacks inside whilst still funneling a cold charge into the manifold.
    Great idea!
     
    AliK and atomman like this.
  3. franky

    franky
    Z Club Member

    Put me down for one if it helps!
     
    atomman likes this.
  4. SeanDezart

    SeanDezart
    Z Club Member
    Official Trader

    Interested...if it fits with the BMC !
     
  5. richiep

    richiep
    Z Club Member

    Superb Gary - love the backing plate!

    What diameter is the intake hole at the front of the airbox? I ask as it looks quite small compared to the Kiddell/MJP airbox like I've got. As I covered in the airbox thread, I'm running 3" ID pipework and air filter. Apparently, 3" works up to around 250bhp. Beyond that, if shooting for bigger stroker territory, it needs to be 3.5", otherwise volume and flow is inadequate (meaning the hole in the rad support needs to be enlarged too). This is based on what Steve Kiddell was running on his 3.0L 300+hp Time Attack 240Z (which now belongs to Matt Bannister/"Racer"). My airbox is around 3.5", with a step-down hose to the 3" aluminium tubing.

    I guess I'm saying make sure the intake end is large enough to step down to 3" but can accommodate bigger.
     
  6. atomman

    atomman
    Z Club Member

    I did measure twice so should clear it Sean
     
  7. atomman

    atomman
    Z Club Member


    Thanks for the info Rich , I have made the inlet end around 85mm but its tapered down to help get the part off the mould so i can also cut it back a bit to make it larger , if you know what i mean,

    In the CAD model at the top , you can see a aluminium flange on the inlet , Idea is that this will bond to the inlet opening to neaten it up and provide a nice seal for the tube to go onto and also can be swapped for a bigger one ,
     
    SacCyclone likes this.
  8. Rob Gaskin

    Rob Gaskin Treasurer Staff Member Moderator

    If using carbs don't forget to provide an air-hole in the backplate for the jets.
     
    atomman likes this.
  9. Woody928

    Woody928
    Z Club Member
    Staff Member Moderator

    As with everything you seem to make, this looks bloody awesome!

    Love the idea of being able to see and show off the trumpets, following with great interest :thumbs:
     
    AliK, SacCyclone and atomman like this.
  10. atomman

    atomman
    Z Club Member

    I dug out some of the flow analysis , this was after a few tweaks like moving the whole air box towards the front of the car a bit and playing round with the radius to sort out the flow on the last trumpet.

    https://photos.app.goo.gl/FAoU9tEm7PBRYMUh8

    Next job is to write a quick spread sheet of data so i can time the inlets opening up with the L6 sequence and drop the pressure on each one to get a better idea, also then i can play round with trumpet length and design if needed ,
     
  11. jonbills

    jonbills
    ZClub Administrator
    Staff Member Moderator

    That looks interesting, where does the data come from? Is it a simulation?
     
  12. tyroguru

    tyroguru
    Z Club Member

    I would love to know more on how you did the analysis here with as much detail as you care to give but the more the better :) . Looks super interesting work!
     
    atomman likes this.
  13. MaximG

    MaximG
    Z Club Member

    And I cant even use the IKEA room design tool for my Daughters bedroom.
     
  14. atomman

    atomman
    Z Club Member

    Yeah its a simulation, using the CAD models I have designed for the trumpets and air box, you build an assembly model of all the bits and you basically seal the box with lids, the outputs and inlet, and assign flow to them , like mass or atmospheric pressure and you can run it up and see how it all flows , turbulence, vortex's and loads of other cool things you can do with it, The more data you give it the better results ,.

    I'm gonna try and measure the flow through one of my carbs and get some data at different rev's and i should be able to stick that in a spread sheet and use those numbers to run the simulation and get better results then , its a bit different to what i usually do but I like a challenge
     
  15. jonbills

    jonbills
    ZClub Administrator
    Staff Member Moderator

    Thanks Gary, I'm very interested to see where this leads.
     
  16. franky

    franky
    Z Club Member

    I'm gonna try and measure the flow through one of my carbs and get some data at different rev's and i should be able to stick that in a spread sheet and use those numbers to run the simulation and get better results then , its a bit different to what i usually do but I like a challenge[/QUOTE]

    45mm?
     
  17. atomman

    atomman
    Z Club Member

    40's with 36mm chokes at the moment
     
    franky likes this.
  18. atomman

    atomman
    Z Club Member

    Just found this on you tube



    This is the type of thing I'm trying to do
     
  19. atomman

    atomman
    Z Club Member

    Went to visit my friend last night and he has finished shaping the plug and has put a couple of coats of epoxy over it ,
    DSC_2084.JPG
    Next job is a light sand to key it up and then some more epoxy and a few layers of cloth to make it solid, then I can polish it all up and think about putting some mold release wax on and getting the first part off it.

    Hope fully next week
     
    Rob Gaskin and tyroguru like this.
  20. IbanezDan51

    IbanezDan51
    Z Club Member


    Is the spacing for the DCOE Webers the same as Jenvey? I am sure it will be?

    Would you be happy to make me another base? Obviously more than happy to pay you for your time, material cost and use of the kit!

    Dan
     

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