40mm Intake Horns to match BBBs.

[vortex2450]

So I've been contemplating fabbing up big bore intake horns to replace the stock horns since I believe that the engineers knew what they were doing as far as intake tuning goes and that removing the horns to install BBB's is less than ideal. I've been drawing up a plan to have a set made for myself but since it could be potentially cheaper if I made a batch I was curious as to who would be interested?

I don't have any solid figures yet but it looks like it will cost about $80 to make just one set w/ materials. I plan on making new flanges from 10-12 gauge 6061 al and the horns will be ~40.23mm ID 6061 tubing. I will weld them myself with a industrial quality TIG welder so I while I'm no pro I am half decent with it. They will be flared just like the stocker and I will have them bent as close to spec as possible.

I plan on eliminating the stock in/out fitment for an outside groove weld and then porting the inside joint together for best airflow.

Well, I just wanted to throw that out. I don't want any money now but if it seems a few people want a set I will go ahead and plan on making multiple runs.

Thoughts?

-Josh

 

[zach44102]

Make me a new intake manifold that has 2 short runners for each cylinder instead of long and short.

 

[92sho16]

So I've been contemplating fabbing up big bore intake horns to replace the stock horns since I believe that the engineers knew what they were doing as far as intake tuning goes and that removing the horns to install BBB's is less than ideal. I've been drawing up a plan to have a set made for myself but since it could be potentially cheaper if I made a batch I was curious as to who would be interested?

I don't have any solid figures yet but it looks like it will cost about $80 to make just one set w/ materials. I plan on making new flanges from 10-12 gauge 6061 al and the horns will be ~40.23mm ID 6061 tubing. I will weld them myself with a industrial quality TIG welder so I while I'm no pro I am half decent with it. They will be flared just like the stocker and I will have them bent as close to spec as possible.

I plan on eliminating the stock in/out fitment for an outside groove weld and then porting the inside joint together for best airflow.

Well, I just wanted to throw that out. I don't want any money now but if it seems a few people want a set I will go ahead and plan on making multiple runs.

Thoughts?

-Josh

You've peaked my intertest, how many takers do you need to get this going?

 

[kevinspann]

If you can make them, I'll buy them for that. I have my doubts though...

 

[intimdatr]

What he said! ^

 

[vortex2450]

Make me a new intake manifold that has 2 short runners for each cylinder instead of long and short.

Ahhahaha. No.

You've peaked my intertest, how many takers do you need to get this going?

I really don't need any, as I will do one beta run first for myself to work out the flaws and then after that I am sure I can make as many or as few as needed.

If you can make them, I'll buy them for that. I have my doubts though...

That # is only an educated guess. The most expensive part is the flanges, I would look into using the stock flanges but that means I'll need cores and I'll have to have someone else TIG them up (I'm not that good) so that is an option.

What he said! ^

I'm ordering the tubing needed Monday and hopefully will have it by the end of that week and then I'll need to get it bent and flared. From there I'll have to weigh the options on custom flanges (cost more in material + cutting them) vs reusing the stock flanges (requires cores and the cost of a professional to TIG weld it.)


If I get 5 interested I'll post pictures and details of the first result and go from there.

-josh

 

[kevinspann]

I've got, and have thrown away sets of stock horns.

 

[intimdatr]

Ive got my stock set.

 

[vortex2450]

Alright, I will assume most people will have a core laying around so I'll just go that route since it eliminates the extra time and money needed to make flanges.

-Josh

 

[notbange]

I'd be down.

 

[frosho]

Interested if that price is close to realistic.

 

[93rev2sev]

I think you'd have to use actual Mechanical Engineering to get these runners to be the right length. If you change the port size, the length will need to change, too...maybe not by much, but still...the whole point of making these is to get the port length correct...not simply to accommodate BBBs.

 

[SHOPLUS]

I think you'd have to use actual Mechanical Engineering to get these runners to be the right length. If you change the port size, the length will need to change, too...maybe not by much, but still...the whole point of making these is to get the port length correct...not simply to accommodate BBBs.

I agree but the idea is that the horns provide more efficient and smoother intake of air. Therefore, with a horn that is even stock length would be an improvement over no horn at all. In other words, keeping it stock length and enlarging the port simply keeps the functionality of the horn (though now maybe not as efficient by a maximum loss of 10% as BBB are not all that much larger than stock ones) while eliminating the bottleneck the stock horn presents. By "loss in efficiency" I mean efficient allocation of air in regards to runner length.

Basically, over all efficiency should theoretically be increased by these horns over no horns and factory horns in conditions where honed/bored runners and larger butterflies are installed. In all reality, to say the horn's length must change due to an increase in inner diameter is like saying when you port your heads out you have to install runner spacers.....

I'd be down for a set in the ball park of $80 assuming it actually makes a difference versus no horn

 

[vortex2450]

I think you'd have to use actual Mechanical Engineering to get these runners to be the right length. If you change the port size, the length will need to change, too...maybe not by much, but still...the whole point of making these is to get the port length correct...not simply to accommodate BBBs.

This has crossed my mind as well but the clearance of stock horns in the intake as already tight, there isn't a ton of room for length here but since I've seen no options offered thus far I'm gonna try and at least get the intake back to a good spec. Maybe they'll even be worth a few hp, the only down side is that they might muffle some of the noise from BBB's since the air is not as turbulent.

Anyways, I'm going to has out the details about the bends today. My living situation is about to change so that might cause a little delay in my plans.

We will see.

-Josh

 

[intimdatr]

My main thought on them is they will hopefully put some of the low end back end. Ive been driving back with my stock y pipe and man is it nice to have that low end grunt over a SHOsource Catless.

 

[SHOPLUS]

My main thought on them is they will hopefully put some of the low end back end. Ive been driving back with my stock y pipe and man is it nice to have that low end grunt over a SHOsource Catless.

Throw some cats in it and call it a day :wave:

 

[intimdatr]

Throw some cats in it and call it a day :wave:

Lol i but i love my taurus with a bunch of hornets up its ****!

 

[vortex2450]

First hitch, apparently the tech I talked too on the phone didn't know the difference between a crush bend and a mandrel bend so I wasted my time riving up there to find out they only have crush bending stuff.

So I'm back on the hunt for a reliable mandrel bending service.

-Josh

 

[NovaSS]

http://www.shoforum.com/showthread.php?t=92099&highlight=custom+air+horn


http://www.shoforum.com/showthread.php?t=95635&highlight=air+horn&page=2




search engine , its not so much as making a proper airhorn, its being able to install it after its made

 

[vortex2450]

http://www.shoforum.com/showthread.php?t=92099&highlight=custom+air+horn


http://www.shoforum.com/showthread.php?t=95635&highlight=air+horn&page=2




search engine , its not so much as making a proper airhorn, its being able to install it after its made

I was aiming at something to replicated the stock horns and would bolt on/off just as the stock horns did. The flare may be an issue with larger diameter horns. I'll work it out.

-josh