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David
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Inlet Runners for a 3.0L conversion

Post by David »

I'll post the steps I used in building the new inlet runners. It may be useful to others wanting to do the same thing, particularly if you only have home workshop tools and can do a bit of basic welding.

David
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41mm ID exhaust pipe, mandrel bent to keep ID through the bend. Bend is 35 degrees.
41mm ID exhaust pipe, mandrel bent to keep ID through the bend. Bend is 35 degrees.
I1.JPG (19.24 KiB) Viewed 9172 times
Chisel out the remaining bit. Not as hard as it looks as the flanges are brazed to the pipe and comes away quite easily. The bronze is also easy to grind out to take the larger pipe.
Chisel out the remaining bit. Not as hard as it looks as the flanges are brazed to the pipe and comes away quite easily. The bronze is also easy to grind out to take the larger pipe.
F3.JPG (20.82 KiB) Viewed 9173 times
Cut the flanges off the original runners. Leave a bit of pipe sticking out to get the chisel behind.
Cut the flanges off the original runners. Leave a bit of pipe sticking out to get the chisel behind.
F1.JPG (10.57 KiB) Viewed 9172 times
Last edited by David on Tue Dec 21, 2004 11:22 pm, edited 1 time in total.
1985 GTV6 3.0 Zender Body Kit - Red
David
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Post by David »

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Press fit them into the flanges.
Press fit them into the flanges.
I5.JPG (10.33 KiB) Viewed 9161 times
I made up a small jig to get the angle right,
I made up a small jig to get the angle right,
I4.JPG (21.1 KiB) Viewed 9162 times
Cutting the correct length and angle was the hardest part.
Cutting the correct length and angle was the hardest part.
I3.JPG (16.45 KiB) Viewed 9163 times
1985 GTV6 3.0 Zender Body Kit - Red
David
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Post by David »

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David
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Finished
Finished
I10.JPG (34.54 KiB) Viewed 9151 times
Cut off flat and coat as required.
Cut off flat and coat as required.
I9.JPG (27.66 KiB) Viewed 9153 times
Line them all up and tack in place.
Line them all up and tack in place.
I6.JPG (34.12 KiB) Viewed 9151 times
1985 GTV6 3.0 Zender Body Kit - Red
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SamW
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Post by SamW »

That is beautiful! How much is that going to cost someone if you end up with nothing better to do than supply other people with that?
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Steve R
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Post by Steve R »

Cool, looks pretty straighforward !

Did you also enlarge the 6 Plenum outlets ? & how ?
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Post by David »

Sam,

If I had a choice that's all I'd do is work on GTV6's, but the bills have to be paid.

When I win Lotto, that's what I'll do. HaHa :D

David
1985 GTV6 3.0 Zender Body Kit - Red
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Post by David »

Steve,

The best you can get from the 2.5 plenum is 39-40mm, which I still think is enough for a stock 3.0L. The "flange" inside the original 3.0L runners is actually close to the ID of the 2.5 reamed out runners.

I used a good quality USA straight edge "reamer", not sure what they're called but they rip out the alloy quickly. I also used this to ream out the inlet flanges. The attached photo shows the 2.5 plenum and the tool.

David
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PL1.JPG
PL1.JPG (16.41 KiB) Viewed 9109 times
1985 GTV6 3.0 Zender Body Kit - Red
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Barry
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Post by Barry »

:D David,good stuff mate! You might want to contact Patrick Centurion in Sydney.He might be keen on a set from you.He`s fitting a 166 motor into his gtv..Will mail you his contact.

Barry
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Post by Seb »

Great stuff David!

So the 2.5 plenum has a limit of about 41mm id? Will it limit the flow a lot if mounting 45mm id runners and only using a 41mm plenum opening?

On my 164 3.0QV plenum I´m using the runners are 45mm id and openings in the plenum to match. Should be prutty good then huh?
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The plenum has been modified to work in the GTV6. Cut off a bit and with a 180 bend to go with it...,
The plenum has been modified to work in the GTV6. Cut off a bit and with a 180 bend to go with it...,
Sebbans plenum kopia1.JPG (71.97 KiB) Viewed 9098 times
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Zamani
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Post by Zamani »

Fantastic Job!!!
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Andrew.b
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Post by Andrew.b »

Nice job mate.....well done!
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