My twin ram intake horn(with pictures)

[Cummins Driver]

Hey guys. Me and Teddy Bear have talked about these things some, and I decided I would try my hand at building one. Im not machinist or fabricator. Just had to use standard tools like a drill press, plasma cutter, grinder, and mig welder(no gas). I am pretty happy with this so far. All of the measurements seem to be good as far as getting it on the truck. I have not test fitted it to a truck yet, but I did bolt the intake plate to a cummins 5.9 12 valve engine we have in the shop with no injection pump to make sure all of that will bolt up fine. Some of the holes are slightly egg shaped, and the big 3" holes arent as nice as i would like, but its hard to make perfect holes without special tools and machinery. One thing i dont like about most of these twin ram intakes i have seen so far is that you cant easily take your DV's out or adjust the afc/plate because of the piping that comes over the injection pump. So i built mine a little more compact, and it has a flange that will have the piping from the I/C pipe to the intake horn welded to so that with 3 bolts it will come right off for fast swaps and adjustments. I still have to build that pipe, but i will have to put it on a truck before i can finish building that part of it, and that should be the easy part. Also, since this intake feeds the #2 and #5 cylinders instead of the #2 and #4 cylinders, you cant use the stock fuel filter setup, but i figured all the cylinders would see more even flow with this setup.

Let me know what you guys think. Dont be too hard on me thoughLOL

Ill definately have pictures once it is painted and on a truck. I think Teddy Bear wants it, and if not, ill probably sell it to someone else? I dont want to get rid of my stock filter setup or grid heaters yet, or i would try it on mine.

Eric

 

[TMONEYDIESEL]

I like the Hellmann style better,

 

[YkDave]

Good for a first try, but needs some major work!

You will get some brutally mad turbulence in that thing and it will likely flow like crap because of it. You need to design the horn in such a way that it will smoothly and evenly divide the airflow rather than having it hit a flat wall and be forced in either direction.

 

[Rollin Coal]

the plate is warped to all hell too, those bolts get tightened to 18 ft/lbs. if you can get it to seal, its probably going to have to be tightened damn close to breaking the ears off the head.

 

[TMONEYDIESEL]

:hehe: I was trying to be nice but these guys are completely correct

 

[Muddin_dude06]

I think it really isn't too bad, I do agree that the flow is going to be decreased by the "dead heading" into the 3" elbows. And I would take it to a machine shop to have the flange machined flat.

Other than that I think it is pretty cool!

I plan on building something very similar but splitting the flow a little more "gently".

 

[Big Blue24]

I don't think you will have turbulence problems once you have a little boost flowing through there.

It's just no boost or off idle performance that suffers from turbulence in these motors.

 

[Cummins Driver]

Yes, the plate is slightly warped. No big deal. Ill get it as flat as i can, and if i need to, ill take it to the machine shop and have it milled. Welding it is what caused it to slightly warp, and it is only on the ends of it and not in the middle so it shouldnt be too hard to deal with.

As for the flow, you guys need to quit thinking like this is a gasser. Its a diesel with 50-60psi of boost running through it. I dont really think the air is going to have a hard time figuring out where to go. Like BigBlue24 said, off idle and initial spoolup should be the only time it would make any noticeable difference at all. You guys do realize that with the stock setup or any setup where the stock plenum is in place, the air runs straight down into a wall and then 90's into the intake runners.

MuddinDude: Thanks, I appreciate it. Im pretty happy with it, and as long as the plate doesent cause any problems getting it good and flat, I think it will work pretty good.

Eric

 

[BlackSkyRacing]

I think I may steal your idea for quick removal with two 3" ferrels like used on milk line in barns... Then it would just be three clamps and the intake is out of the way :Cheer:

 

[BluegrassDiesel]

I like the Hellmann style better,

His is prettier, but this one cost $61 instead of $500. Plus you have to take the whole plate and injector lines off every time you want to easily access the afc housing for adjustments to either the AFC or the plate. Not saying that Hellman's is a bad piece, or that this one will perform better.

Im not sure how it will work out, but I dont see how it can be all that bad. Im definitely gonna try it out just to see how it does.

 

[SINNER]

As for the flow, you guys need to quit thinking like this is a gasser. Its a diesel with 50-60psi of boost running through it. I dont really think the air is going to have a hard time figuring out where to go.

You boys need to study up on your fluid dynamics. Air is a fluid you know, Right?

Pipe turbulence becomes exaggerated at HIGHER FLOW not pressure. Pressure is a static measurement so it could sit there with 60 lbs. of pressure on it and the air not move 1 molecule. As the flow of the engine increases with rpm's is when the the dead end is going to be most detrimental. I would say that is worse than the stock part as it sits now.

 

[CC12V]

His is prettier, but this one cost $61 instead of $500. Plus you have to take the whole plate and injector lines off every time you want to easily access the afc housing for adjustments to either the AFC or the plate. Not saying that Hellman's is a bad piece, or that this one will perform better.

Im not sure how it will work out, but I dont see how it can be all that bad. Im definitely gonna try it out just to see how it does.

You might want do do your homework before you go shootin your mouth off about my products.
The only thing I don't like about mine, if you need to do work to the DV's the intake needs to come off. Your comment on the AFC is BS. See attached pic.

 

[haloman]

You might want do do your homework before you go shootin your mouth off about my products.
The only thing I don't like about mine, if you need to do work to the DV's the intake needs to come off. Your comment on the AFC is BS. See attached pic.

Not to step on any toes Joe but to be fair he asked you twice about it:

Hellmann Dual Ram Intake 12V - Competition Diesel.Com - Bringing The BEST Together

 

[Delinquent]

You might want do do your homework before you go shootin your mouth off about my products.
The only thing I don't like about mine, if you need to do work to the DV's the intake needs to come off. Your comment on the AFC is BS. See attached pic.

Wow...I'd like to see these two on a dyno, and I'd bet that there wouldn't be more than a 2 or 3 hp difference between them. And I think Josh's would be the winner...

 

[Rollin Coal]

Wow...I'd like to see these two on a dyno, and I'd bet that there wouldn't be more than a 2 or 3 hp difference between them. And I think Josh's would be the winner...

id bet a loss over stock.

hellmanns i think 2-3% over stock intake on a stock head. more with head work.

 

[LittleRed]

The only thing I don't like about mine, if you need to do work to the DV's the intake needs to come off.

I agree totally with this. Other than that it seem to work well.

 

[YOUNG GUNS15]

for a home buil one it looks alright!! i dont know about how well it will perform but 2-3 hp is not much to bragg about

 

[BluegrassDiesel]

You might want do do your homework before you go shootin your mouth off about my products.
The only thing I don't like about mine, if you need to do work to the DV's the intake needs to come off. Your comment on the AFC is BS. See attached pic.

Joe, I wasnt trying to "shoot my mouth off". I apologize for making a false claim about your product. Still even in that pic thats not exactly what I would call "easy" access. I tried to make sure not to bash your product in my first post. Notice my little disclaimer at the end.

Guys this thread wasnt started to say that this was the end all be all of intake manifolds, or even that it was any better than any other product currently out there. We had discussed trying to make one on our own just to see how it turned out. We'll try it out and if it doesnt end up performing so well, then we can improve on it for next time.

 

[ride42]

\
Guys this thread wasnt started to say that this was the end all be all of intake manifolds, or even that it was any better than any other product currently out there. We had discussed trying to make one on our own just to see how it turned out. We'll try it out and if it doesnt end up performing so well, then we can improve on it for next time.

Exactly. I made mine because I wanted to see if there was anything to be gained, granted it is just a single tube, it still made quite a bit of difference.

What I want to know is, has anyone tried to make an intake horn(s) that would compliment the angle in the manifold? So instead of it hitting and reflecting off of it the air would flow right down it...?

 

[XLR8R]

You mean the entry into the plenum?

Can't do much about that without removing it...:evil