hybrid mini
2.0 16v Vauxhall Powered Mini

Inlet Manifold / Plenum Fabrication

Click on a thumbnail for a full size image.

 

An original XE inlet manifold was cut and machined down by Andy at AMT, he also did an injector boss mod for me to stop the new bosch injector caps falling inside then head, this can be seen in some of the pics.

The tubing I have used is 40mm ID and 50 OD and 5mm thickness for the inlet runners, and 100mm tube at 4.75mm thickness for the bulk of the plenum chamber, 3mm ali plate is used for everything else.  I cut most of the metal and then decided to take some pics after I had tacked it up. 

The design of this inlet manifold / plenum chamber is similar to that which can be bought from HKS for the Toyota Supra and Nissan Skyline, for a small fortune might I add.

 
This is the tubing that I have used large tubing cut in half trumpets to fit webber dcoe's cut down The trumpets fit nicely inside the tube.
Another view The bottom part of the plenum made from 3mm ali plate and some section cut from 100mm tube another view another view
The end cap made from segments of 100mm tube The outside of the end cap This is how the plenum will look The trumpets will be inside the plenum

 

Images below are of the manifold once I had it back from the welder.  I still need to fabricate a flange for the cossie throttle body that I will be using initially, mounting points for a fuel rail will also follow

 
The welding will be smoothed off once the unit is complete The trumpets shown previously now inside 4 inch diameter for a cossie body  
Another view inside