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Welcome to the "Project Pickard Peugeot 106" website! www.ppp-106.co.uk

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Peugeot 106 Rallye S1 Inlet Manifold To suit Yamaha R6 2004 Throttle Bodies
30/06/07
Fistly the available Space is measured:

Engine Bay of PPP-106 Available Height Available Space to Bulkhead

The first picture shows the Engine bay as it is with the existing inlet plenum at the top of the picture up against the bulkhead. To Gauge the available Height a straight edge is placed accross for reference at the level of the carbon fibre bonnet. The tape measure is placed at the top of the maniold entry to the head. This shows we have 150mm of available height at this point. Due to the curvature of the bonnet there is actually more than this available.... There is (from the manifold face) Just under 210mm to the Bulkhead... Which may present a problem for attaining the tuned length requirement for 8500rpm. See the Blinded by Science Page, to be, well, blinded by science!
Cardboard model for the available space!
Carboard cut-out! Cardboard 02!

A cardboard model is made of the available space, from the head manifold face to the bulkhead. Of particular importance is the clearance on the Steering rack - as the track rods move up & down with the suspension. Also is the clearance around the brake connection bar.

Once this template is made it can measured & put into a CAD model to aid the design of the manifold. The Red Translucent block is the representation of the available space.

Available Space Model

After the available space is worked out the design can be started. - Below is one of the MK1 versions. - A cardboard cutout is made of the design to check back on the Car.

Cardboard Engineering!

 

Peugeot 106 Rallye Inlet Manifold Design - Starting From A PTFE Gasket

Engineered By Design ebd Peugeot 106 rallye S1 PPP-106 Inlet Manifold Gasket Original part scanned

3mm Thick PTFE Gasket... Initial Scan: - The Gasket Was Scanned 1:1
Engineered By Design ebd Peugeot 106 rallye S1 PPP-106 PTFE Inlet Manifold Gasket

First Fettle in Art Package: Background Removed

Engineered By Design ebd Peugeot 106 rallye S1 PPP-106 Inlet Manifold and Yamaha R6 throttle bodies rendered Gasket PTFE
And a Model Created in SolidWorks - This was achieved by overlaying the jpeg in the sketch to check dimensions...
Manifold Plate:
Manifold Plate
3D Solid Modeled Manifold Plate, designed to suit The Standard Peugeot 106 8V TU2J2 Head with no modifications
Peugeot 106 TU2j2 Manifold Weld Assembly MKI
 
Manifold Design   Cross Section Of manifold
(click to enlarge)

As Can Be Seen - Designed complete with Bosses for tak off of Vacuum Assist & / Or Measurement Points. The Manifold was designed to suit the pitch on the Head & The Pitch Of the Yamaha Throttle Bodies

 

The Section View Above really demonstrates how the inlet charge flow path would be less than ideal. This is due to the spacing being dictated by the Centres of the throttle Body chokes & The Centres of the inlet ports on the head.

As such it is decided to match the port spacing on the head to the R6 Throttle Bodies, as ports 1 & 4 are already in the right place for this to happen.

Mark Two Redesign... - Lets Get serious on the Head then...
 

The Solution is to modify the Head quite seriously. i.e. to "re-pitch" the inlet ports. The Concept here is two "straighten up" the flow path into the combustion chamber. Whilst maintaing charge velocity.

Head Cut
First Prototype Manifold Design:
 

The concept with the re-pitched head is something like this:

R6_TB Layout

This concept does not fit in with clearance required around the steering rack & where the bulkhead can be most effectively cut. Also the concept to use 8 injectors does not fit in with this design of manifold... To continue a new concept is developed:

 

Concept Redesigned - CAD Design Data:

 

CAD Drawings of Manifold

CAD drawings of revised manifold design. - These CAD models are used to generate the renderings as shown below:

 

Concept redesigned:
 

New Manifold ConceptBright Render   Dark Render

 

Engineered By Design ebd Peugeot 106 rallye S1 PPP-106 Inlet Manifold and Yamaha R6 throttle bodies rendered using Soliworks and PhotoWorks CAD packages Manifold Engineered By Design ebd Peugeot 106 rallye S1 PPP-106 Inlet Manifold and Yamaha R6 throttle bodies rendered using Soliworks and PhotoWorks CAD packages

Cutaway Manifold Manifold Cutaway Dark
 
Pictures of real life alternative design manifold undergoing 1st stage checking:

 

Inlet Manifold fitted to PPP-106 Side on View of R6 Throttle Boddies Manifold & R6 TB's fitted to PPP-106

And as before The CAD models are checked with a prototype on the vehicle itself. The manifold is shown here in its first stage, with only ports 1 & 4 fitted. - This is done to ensure the angle is acceptable and will miss the Bulkhead at the appropriate points where it has already been cut & prepped.

 

Manifold - Tacked up:

PPP-106 - Custom Manifold - Tacked up PPP-106 - Custom Manifold - Tacked up 02 PPP-106 - Custom Manifold - Tacked up 03

PPP-106 - Custom Manifold - Tacked up 04

The manifold is first "tacked-up" to minimise distortion - This is a very important part of the manufacturing process.

And as before The CAD models are checked with a prototype on the vehicle itself. The manifold is shown here in its first stage, with only ports 1 & 4 fitted. - This is done to ensure the angle is acceptable and will miss the Bulkhead at the appropriate points where it has already been cut & prepped.

 

Manifold - Welded Up:
PPP-106 Custum Peugeot manifold welded 01 PPP-106 Custum Peugeot manifold welded 02 PPP-106 Custum Peugeot manifold welded 02
The manifold is first "tacked-up" to minimise distortion - This is a very important part of the manufacturing process.

 

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