I’m building a Fit powered insight and one of my challenges is redesigning the intake manifold as it’s too high for my hood line (Insight). While pricey, the easiest way to harvest the aluminum head and TB flanges was to buy the Weapon R and chopped it. What I discovered was disappointing.


The port holes are about 3mm larger than the head AND about 2mm off centered. The only way to have known this is to destroy the manifold as I just did. While the manifold is known to increase power. Seems like the could have done a much better job. I now have a $430 TB flange.

 

That is disappointing. Especially once you factor in just how simple that part is to get right.

 

Notice the slag on the plenum side, not only bad for airflow but the stuff can break off and go through engine..... garbage.

 

Wow. Garbage indeed

 

wow. unconscionable that they'd sell it like that.

 

Sad because I was thinking that the intake would be a great addition to my turbo build. Even if it does make more power, I don't want something of that engineering/build quality on my car.

 

Wow, thats what I would expect from a $150 manifold. What they charge for that crap quality is beyond ridiculous.
At least now I know not to give them any money.

 

Thanks for showing me this, I'll definitely give mine a thorough inspection when I receive it!

 

ahh man, I have known this for a really really long time :/ This used to be discussed at length in 2 separate threads on here...

 

Is each outlet on the IM offset by that much? I am wondering if this is why my cylinder #3 was receiving less fuel through my wet nitrous jets than the others.

 

Tracing the intake gasket on the head and then intake is a good way to compare.

If the ports don't line up, fuel could be hitting a wall and puddling.

Despite my willingness to buy parts, I haven't bought this manifold until I see proof the the ports line up and match. Too many bad things can happen if they don't.

 

True that. Odd that my number 3 cylinder was the only one leaning, the other 3 spark plugs were rich. Upon further inspection, I found the culprit to my problem...the fuel jet in number 3 BARELY has any hole in it. That definitely explains my results.

 

Ouch! Was it mis-labled? At your jet sizes per cylinder, all of those holes will be itsy bitsy! I've never seen jets for smaller than 75hp per fogger. LOL

I once was tracing a nitrous problem in one of my stages...finally discovered the spray bar was mounted upside down in the plate by the manufacturer. Was causing all sorts of problems!

 

Here are some pics that compare the stock flange to the WR, notice the stock ports are oval shaped and the WR is round and bigger all the way around. This is the same on every port. Also the close ups of the WR show the play in the fit of the flange, One pic is with me pushing the flange up against gravity and the other is free, both are off center in the same direction. This can be fixed with port matching. The gasket also fit the head perfectly as you guys can see.

 

HOWEVER,,, these are closeups of if the plenum ports 4 and 2, 4 is the worse one and it would be different with every manifold and with the right tools may be able to be fixed reasonably?? the other two ports were fine. Not sure if its related to your N02 issues but this will help you decide.

 

Thanks so much for the pics. It may play a part in My problem...the offset holes...But 3 cylinders were rich and the one with the fuel jet being too small, even tho it was labelled the same as the others resulted in a lean enough condition to melt the plug.

 

thats crazy. thanks for sharing.

 

Simply Wow!


This thread has some good info. Thanks for sharing guys.