[PICS] Gen V intake on my Gen IV ACR [PICS]

[FLATOUT]

Wow that looks great! Well done!

[01sapphirebob]

Yes...Very nice indeed!

Makes me want to pick up a GEN V intake for my GEN IV.

[jvm728]

Just a thought, you may want some wiggle room as torquing down the manifold doesn't happen perfectly square and you can't bank on the mold that makes the parts built as the holes are perfectly in line with head flange bolt holes

[SSGNRDZ_28]

Just a thought, you may want some wiggle room as torquing down the manifold doesn't happen perfectly square and you can't bank on the mold that makes the parts built as the holes are perfectly in line with head flange bolt holes

Thanks for the feedback, I will asses this for the next run. I have noticed these aren't necessarily perfectly aligned within the manifold itself due to the inconsistencies within the plastic, but they will align with some force. I may open up the bolt holes slightly or reduce the outer diameter to allow some wiggle room. The bottom line is that this manifold isn't exact as you are aware so the design needs to accommodate that.

[IndyRon]

Doug,
Looking good! If I could make one suggestion though, I would make the aluminum flange on the inserts at least 1-2mm larger in diameter so as to get as much intake flange purchase and distribute the force over as much of it as possible. My initial washers were about the same diameter as your setup there and they were starting to cut into the plastic even after a couple heat cycles and retorquing at 95 in-lbs. I'd have the insert extend all the way to the edge of the manifold at the shortest edge.

Roughly this size:


That raised surface you see in the bolt hole to the left without an insert in it....that raised part will actually collapse and compress even under 70 in-lbs of torque...that's how soft these manifolds are.

[SSGNRDZ_28]

Ron,

Thanks, I'm always open to suggestions. That is good information knowing the raised surface will collapse. That confirms I can make the limiter short enough that torquing down on the bolts will collapse that section but then the limiter will prevent further collapse (the force should be on the limiter at that point). I will look into making the diameter bigger for good measure, my original design was the size you are suggesting but I reduced it not knowing the raised section would collapse.

Thanks to all with experience installing the manifold for the feedback and suggestions.

Doug

[SSGNRDZ_28]

The revised parts arrived today and I was able to test fit them, I'm happy with the results. I took all of the advice into consideration (Ron, I made the diameter as large as possible without raising the cost; jvm, I made the inner diameter larger so that there is slop to account for manifold inconsistencies during installation). I'm going to take them to get anodized tomorrow, hopefully by next weekend I'll be doing the manifold install to confirm they work.

If anyone is still interested (I know of a few that are for sure) I'll be doing a group style purchase in early December assuming all goes well.

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[Mbccenter]

I am interested.

[Dan Cragin]

I am just about to modify the torque limiters for an install, can I get these? 310-597-6295

[TooBlue]

I am interested.

I thought you retired...?

[IndyRon]

Doug,
I'm also interested in a set. Could I get a caliper measurement of the diameter of the limiter face that is torqued down to the manifold?

[FrgMstr]

I am just about to modify the torque limiters for an install, can I get these? 310-597-6295

I trimmed all by hand to fit perfect. Retorqued one time, never had an issue.

[SSGNRDZ_28]

Doug,
I'm also interested in a set. Could I get a caliper measurement of the diameter of the limiter face that is torqued down to the manifold?

Ron,

The max diameter is 0.656" and the flats are 0.590" across.

[SSGNRDZ_28]

I am just about to modify the torque limiters for an install, can I get these? 310-597-6295

It was great talking to you Dan, they will ship out today. Looking forward to your feedback!

I trimmed all by hand to fit perfect. Retorqued one time, never had an issue.

I agree, if you have the time and the skill, hand trimming will work. Your install helped verify the concept (thanks!). Hopefully this product helps those who aren't comfortable doing so, who don't have the time. One benefit from Dan's perspective might be that he doesn't have to wait for each manifold to come in, remove the limiters, have them machined, and then install the manifold - he can have these on the shelf and therefore a quicker turn-around for his customers.

[FrgMstr]

I agree, if you have the time and the skill, hand trimming will work. Your install helped verify the concept (thanks!). Hopefully this product helps those who aren't comfortable doing so, who don't have the time. One benefit from Dan's perspective might be that he doesn't have to wait for each manifold to come in, remove the limiters, have them machined, and then install the manifold - he can have these on the shelf and therefore a quicker turn-around for his customers.

I totally get you on this. Would be nice to have a quick product replacement for sure. For guys that like to get their hands dirty in the garage, and I get that is not all Viper owners by a long shot, surely they can do it themselves. I worked in and around the plastics industry for 10 years, and I was not about to install that intake without those supports, just know what plastic does over time in an environment with huge temperature deltas. Quite frankly, your design with the top flange is better that OE for sure. We are lucky to have guys like your in our community. Kudos!

Funny thing, I found your speaker panel deletes this week after making my own. Thanks for nothing!

[SSGNRDZ_28]

I totally get you on this. Would be nice to have a quick product replacement for sure. For guys that like to get their hands dirty in the garage, and I get that is not all Viper owners by a long shot, surely they can do it themselves. I worked in and around the plastics industry for 10 years, and I was not about to install that intake without those supports, just know what plastic does over time in an environment with huge temperature deltas. Quite frankly, your design with the top flange is better that OE for sure. We are lucky to have guys like your in our community. Kudos!

Funny thing, I found your speaker panel deletes this week after making my own. Thanks for nothing!

Thanks, Ha! I saw that thread early on, but didn't know you'd be removing your speakers or I would have mentioned something. I guess people can't buy something they don't know exists!

I like getting my hands dirty but I'm not necessarily a skilled fabricator so drawing parts up in CAD and having them manufactured is my preferred approach for things other than the most simple of parts. I know what my strengths and weaknesses are .

[Steve M]

Put me solidly in the interested category.

[FastMatt]

The prototypes arrived today. Good news / Bad news.

They fit very nicely around the bolt and are snug in the manifold. The bolt does not wobble around at all as with the OEM version. I Think these will work well for their intended purpose. The flats are nice to have to orient the limiter once it is completely pushed into the hole. The bad news is that I want to tweak some of the measurements of the angle to make it a more perfect fit, so that means more waiting before the install.

Right now it looks like about 5 people are interested, here's the price breakdown. If there is more interest the cost will go down for everyone. Note the final version will be anodized black.

QTY 5: $135 / set
QTY 10: $110 / set
QTY 20: $100 / set

I will take a set of you still have some.

[Chorps]

The revised parts arrived today and I was able to test fit them, I'm happy with the results. I took all of the advice into consideration (Ron, I made the diameter as large as possible without raising the cost; jvm, I made the inner diameter larger so that there is slop to account for manifold inconsistencies during installation). I'm going to take them to get anodized tomorrow, hopefully by next weekend I'll be doing the manifold install to confirm they work.

If anyone is still interested (I know of a few that are for sure) I'll be doing a group style purchase in early December assuming all goes well.

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Still interested

[TexasTonka]

I'm interested in a set as well

[TooBlue]

Please add me to the list.

Thanks again SSGNRDZ_28 for taking the time to make these. These will be going on a track car which as you know goes to the extremes of hot/cool periods 4-5 times a day. Ideal situations for possible problems maintaining bolt torque on a plastic part.

Not to be rushing you in any way but when do you think these might be ready?

[SSGNRDZ_28]

No problem. Right now I'm waiting on either Dan or myself to confirm they fit well and go through the entire install process to account for anything unexpected. That will probably be next week at the earliest.

If that all goes well I'll go ahead with the production run. That usually takes 4-6 weeks, if anyone doesn't want anodizing I can send them out about 1 week quicker. That puts us at the end of December or early January. Right now it looks like I have interest in 9-10 sets.

[TexasTonka]

No problem. Right now I'm waiting on either Dan or myself to confirm they fit well and go through the entire install process to account for anything unexpected. That will probably be next week at the earliest.

If that all goes well I'll go ahead with the production run. That usually takes 4-6 weeks, if anyone doesn't want anodizing I can send them out about 1 week quicker. That puts us at the end of December or early January. Right now it looks like I have interest in 9-10 sets.

How did the installs go? Ready to install a GenV intake on my replacement ACR. I had an SRT shop install my last Gen V intake on my other ACR, then cut them down by hand and i had to re torque the intake a few times to get it to finally seat. This part looks great and if it works on teh car as in theory I am all for it to install my intake on the new car.

I have ordered a new GenV intake for the replacement ACR and do have a quick question. The intake I bought and installed on my ACR last year was part# 5038554AD, that part number has been replaced with #5038554AE. I am sure all your measurements and data are off the AD part number as the AE replaced it for 2015. Does anyone know what the change is in the intakes? Will your parts work in the new part number?

I can't see them changing the bolt flanges of the intake at all, I am thinking they may have increase or 'ported' the intake itself a bit requiring a new part number to be established and justifying the 5hp increase in the 2015 stats?

[SSGNRDZ_28]

My parts came back from anodize late on Wednesday and I'm out of town until Saturday so I've not had time to do the install. I haven't heard from Dan so I'm not sure if he was able to make progress.

As for the new manifold P/N I'm not sure, please report back on any differences when you receive it, if need be I can send you a sample part (I have a few extra) to confirm they will fit.

Thanks for your interest and paitence.

Doug

[TexasTonka]

My parts came back from anodize late on Wednesday and I'm out of town until Saturday so I've not had time to do the install. I haven't heard from Dan so I'm not sure if he was able to make progress.

As for the new manifold P/N I'm not sure, please report back on any differences when you receive it, if need be I can send you a sample part (I have a few extra) to confirm they will fit.

Thanks for your interest and paitence.

Doug

Will do- part should be here next week.