N52 Swap Discussion

[Northern]

It's still not very economical to 3D print a manifold that will actually last long term . Some of the less critical areas of the manifold would work fine. Bolting to the head no way. A Cnc or cast adapter is the way to go IMO depending on quantity

We had a full (ie. from behind single throttle body to port) single-piece 3d printed intake for a CBR600RR in an old iteration of our FSAE car, probably ~2012ish. I think it survived 3-4 engines (~1 engine per year... lol) and seems to be in good shape after being thrown around the past 4 shops we've had. Seems at least as robust as an e36 intake. It was a sponsored part made by Realize Inc. I think they're super common now in FSAE. Sure it's not the same as 200k+ on a production engine, but I think there's a reasonable possibility it would last.

I 100% agree that it's not economical though.

[Motheye99]

We had a full (ie. from behind single throttle body to port) single-piece 3d printed intake for a CBR600RR in an old iteration of our FSAE car, probably ~2012ish. I think it survived 3-4 engines (~1 engine per year... lol) and seems to be in good shape after being thrown around the past 4 shops we've had. Seems at least as robust as an e36 intake. It was a sponsored part made by Realize Inc. I think they're super common now in FSAE. Sure it's not the same as 200k+ on a production engine, but I think there's a reasonable possibility it would last. I 100% agree that it's not economical though.

What was the material? I built my own printers and while they're not close to commercial printers. THey've got the capabilities for 400+c° prints.

[digger]

We had a full (ie. from behind single throttle body to port) single-piece 3d printed intake for a CBR600RR in an old iteration of our FSAE car, probably ~2012ish. I think it survived 3-4 engines (~1 engine per year... lol) and seems to be in good shape after being thrown around the past 4 shops we've had. Seems at least as robust as an e36 intake. It was a sponsored part made by Realize Inc. I think they're super common now in FSAE. Sure it's not the same as 200k+ on a production engine, but I think there's a reasonable possibility it would last.

I 100% agree that it's not economical though.

I'm interested in the material to. The complicated part is adding metal inserts for the mounting bolts to stop relaxation.

[nando]

Why an adapter? It bolts up, why not port out the N52 head to match the throttles? The ports and, I @$$ume, the valves are smaller than S54's, but we don't yet know if the N52 head can be improved to perform closer to an S54 head. I suspect that someone looking to swap on S54 throttles could afford a head/throttle package.

because a spacer (about 1" thick) is needed anyway in order for it to clear the OFH.

[wazzu70]

Material: http://www.windform.com/


Example: https://www.crptechnology.com/intake...-xt-vm-motori/

[Motheye99]

Material: http://www.windform.com/ Example: https://www.crptechnology.com/intake...-xt-vm-motori/

That would certainly work. I don't think I print that material. I really need to buy a s54 TB and get to work on this.

[Northern]

What was the material? I built my own printers and while they're not close to commercial printers. THey've got the capabilities for 400+c° prints.

Our team has no documentation to go with it. There was a team reboot in 2015, and 99% of what came before that is gone.

Here is their materials page: https://realizeinc.com/materials/

I think they mostly did SLA in that era, but I don't know what resin. I think there has been some evolution in 3d printing since this was made too

[wazzu70]

That would certainly work. I don't think I print that material. I really need to buy a s54 TB and get to work on this.

Im 99% sure you don’t have a hobby laser sintering machine :) They are starting to make more affordable printers so its possible to have one at home. Definitely not the run of the mill 3D printer!

https://en.m.wikipedia.org/wiki/Selective_laser_sintering

[nando]

I was going to say - that looks cool, but sounds expensive.

[Motheye99]

I'm interested in the material to. The complicated part is adding metal inserts for the mounting bolts to stop relaxation.

I've used these before. They would even somewhat replicate the OE plastic intake manifold. Of course i'd have to heat them up a bit more for the filament I plan to use.

[Motheye99]

Im 99% sure you don’t have a hobby laser sintering machine :) They are starting to make more affordable printers so its possible to have one at home. Definitely not the run of the mill 3D printer!

https://en.m.wikipedia.org/wiki/Selective_laser_sintering

Its only a matter of time before we get a DIY SLS solution. Filament based printers have plateaued.

Defiantly a ways to go before i can make my own intake!

https://reprap.org/wiki/OpenSLS

[jeenyus]

I didn't know where else to pose this questions, so i'll post it here.

I noticed recently that the N54 is a rear oil sump. Would this mean that you could basically drop that into an IX? If you wanted to bastardize the IX and make it RWD with an N54 (because the front subframe is oriented further toward the front)? would that be possible you think (in theory?)

[nando]

Yeah, I've test fitted it (N52 pan is the same). It fits really well.

[jeenyus]

Yeah, I've test fitted it (N52 pan is the same). It fits really well.

So the ix (ironically) is perfect for an N5X swap IF you're willing to become RWD? That's kind of crazy.

[nando]

I've considered it. Just to get it moving... But really I just need time to build a motor.