Phenolic Intake Manifold and TB spacers for the SVX/EG33 available

[Stevebsy]

Big thanks to Nate for the push and help.

On the way to me are a set of gaskets, from which I will program and cut on my CNC, sets of phenolic spacers.

I will make them for the manifold and the throttle body.

I need to figure out a few details:
Thickness

Length of replacement bolts to match increased thicknesses

Which exact grade of phenolic to use



Any comments, suggestions, discussion before I get too far down the rabbit hole?

[theflystyle]

Great to hear... but what are the costs looking like?

[Stevebsy]

I think costs will be reasonably in line with those for other cars.


I plan on selling a complete package of the spacers, gaskets, and longer bolts as required.

[svxfiles]

Originally Posted by Stevebsy

Big thanks to Nate for the push and help.

On the way to me are a set of gaskets, from which I will program and cut on my CNC, sets of phenolic spacers.

I will make them for the manifold and the throttle body.

I need to figure out a few details:
Thickness

Length of replacement bolts to match increased thicknesses

Which exact grade of phenolic to use



Any comments, suggestions, discussion before I get too far down the rabbit hole?

The Outlaw Engineering ones were 1/3" thick.
The upper ones are easier to make and install, the lower ones have more of a heat-limiting effect.
I see no heat-related reason for the throttle body spacer.
Once the spacers are installed knock sensors and under manifole hoses are easier to get to and the intake temperature drops ALOT!
Some of us are anal/thorough, and are particular about the bolts we install.
I have a bunch of pictures in my locker from Chi'kes phenolic body install.
I think this should help.
Tomhttp://www.subaru-svx.net/photos/use...svxfiles|24784

[Scoobyru]

Originally Posted by Stevebsy

Big thanks to Nate for the push and help.

On the way to me are a set of gaskets, from which I will program and cut on my CNC, sets of phenolic spacers.

I will make them for the manifold and the throttle body.

I need to figure out a few details:
Thickness

Length of replacement bolts to match increased thicknesses

Which exact grade of phenolic to use



Any comments, suggestions, discussion before I get too far down the rabbit hole?

i'd be interested in a set too

[Svx95]

Originally Posted by Stevebsy

Big thanks to Nate for the push and help.

On the way to me are a set of gaskets, from which I will program and cut on my CNC, sets of phenolic spacers.

I will make them for the manifold and the throttle body.

I need to figure out a few details:
Thickness

Length of replacement bolts to match increased thicknesses

Which exact grade of phenolic to use



Any comments, suggestions, discussion before I get too far down the rabbit hole?

When I looked into getting these made I did a bit of research, and altough I called GrimmSpeed the person I talked to didn't know the grade of the phenolic material. However they asked for my number and email so they could get back to me.

About 2 weeks later I got an email stating that they use Phenolic G10 GRE (Glass Reinforced epoxy). "G10 phenolic is mechanically stronger and provides the best in thermal transfer resistance translating into lower temps and more power."

I looked into it and this stuff can maintain a safe environment up to 500*F, can handle race fuels, E85 and methanol.

The two thicknesses Grimmspeed carries are 3mm = .118 inches & 8mm =.314 inches. Obviously thicker means better cooling and greater volume of air in the intake manifold.

Just like svxfiles mentioned below, the Outlaw Engineering ones were .333 inches = 8.4mm. Cooling should be about 20-40*F depending on ambient temps.

As to the "Length of replacement bolts to match increased thickness" question. The NEW bolts need to be 5mm longer than the stock ones.

Also, the cost for Outlaw Engineering spacers was $105 and that included the intake manifold & throttle body spacers, shipping, gaskets, hardware and stickers for 20+ AWHP . Obviously, it wasn't enough since the company flopped.

I think somewhere around $115-$130 shipped would be reasonable for the intake manifold and throttle body spacers!

You have a happy customer here (SVX oil cap) and can't wait to do business again (Spacers).

[SVX92-97]

I will be anxiously awaiting there availability OT, maybe I can take a ride down your way when these are ready and give you a little PT on that finger

[bishop]

I'm gonna need a set of these eventually too.

[scoobydrvr]

Just my $0.02:
I looked into having these made here in town and the biggest thing I ran into was the difficulty involved with milling the phenolic material. Most traditional CNC machines won't tolerate much work on the stuff because it is so abrasive. It'll wear out your tool very quickly. The other problem is that the dust is carcinogenic! The one place I can source the material locally has to shut down their shop, clean everything, cut the material, and clean everything again before they can resume the work.
I'm not sure what kind of a CNC setup you have but I hope it can tolerate this kind of material. A water jet will be your best bet if you have access.
Additionally, the G10 GRE that Svx95 mentioned also goes by the name of "FR-4" and "FR-5". They aren't quite the same stuff but almost identical in terms of performance to G10 (the "FR" stands for Fire Retardant). FR-5 has a higher temperature tolerance than FR-4 but both will work for normal applications. You might be able to keep costs down by using FR-4 instead of FR-5 for stock applications; my local supplier wanted substantially more for 5 than 4.
Do you need CAD files of the gasket cutouts or have you already made those?

[Stevebsy]

Yes..it is nasty stuff to work with, I have worked with G10 before in previous jobs building composite stuff.

I have some gaskets on order, but if you or anyone else has files, I would love to have them so I don't have to make them myself.

Hope to be cutting the first set within a couple weeks....

[scoobydrvr]

Happy to help with that. Any chance we can work out a deal for the assistance?

[Stevebsy]

Something will be arranged

Did you make those files yourself? Just curious to their origin..

Thanks!

[Stevebsy]

Whoop!

The file is programmed and ready for the mill. Also..my OEM gaskets shipped today.

I plan to head to the shop tomorrow and mill a sample out of some plastic sheet I have, just to check the dimensions, etc. and make sure all is well.

If good, then it's time to order some material and make some dust. (and a price list)

What are the group thoughts? I can supply these with or without gaskets, I could use Subaru gaskets or aftermarket, many options... I will include the longer bolts in any kit option.

[svxfiles]

I only like Subaru for the intake manifold gaskets.
Not cheap but very good sealing.
What thickness are you going with?
Tom

[SVXRide]

Would you be willing to make a one off set of 1/2-3/4 inch thick spacers that would go between the intake manifold and the injector stacks?

Thanks
Bill