Damn! Fantastic fab work and then some.Love this build...

Lets start to build the intake manifold.
After extensive searches I was not able to find anything like this been made.
So first one of its kind. Same sad Kenne Bell and few twin screw specialist from Sweden witch turns out to be great help in this.
Twin screw supercharger was invented in Sweden by Alf Lysholm.
Thats why all twin screws are referred to as "Lysholms"
But Kenne Bell is the only one with Lysholms/Autorotors idea, with 6 by 4 rotor pack design. Far superior to others in my mind.
I feel lucky, as I've had a chance to visit supercharger factory three times.

You will found out that this build is highly dependent of friends..
Man, it good to have alot of skilled friends..

First I set the blower on the engine with piece of I-beam..just to get visual reference.

At that point I had 4.2L blower, witch I did installed to 572 Hemi. But thats another story.

Next I started to draw 1:1 scale plan what kind it need to be.
What kind of air space will I need and get.
Bottom floor spoilers where an a idea but tno needed them.
I already had my special made intercooler core arrived from Europen core factory.
I ordered it as 2 stack 50mmx100mmx500mm( 2"x4"x25")
So it will have two cool shocks, instead of one thicher core. That could suffer from heat soak more.
Capacity to cool over 2000Hp.
With ambient cooled water/coolant.
On the sided I need space for Bosch Ev-14 (1500cc) injectors, one per cylinder.

Under the stock intake is coil packs, couple knock sensors and some cast bosses. They all need to go or atleast relocate.

First plan was to machine it out of 6061 billet, thanks to near by top cnc shop. again one of my friend worked there as sales manager. But when he quit, so did my hopes for billet intake.

Next idea was to make molds and cast it from aluminium with yet another friend. Hes been doing molds and casting (mainly stainless) past 20+ year.

We where just about to start fabbing the molds when yet another friend offered to help. He has huge new cnc-press brake. 100.000t, that 1 million kilograms. 2mil lbs.
So we made the base plate with that. From fresh 10mm plate.
Bend it like it was A4 printer paper. LoL
But right on the money. Great!
I was educated that aluminium ages, old plate brakes..

Now I've made welding jig, from 15x150mm I bean, cutted in half, welded it to 50x100 with 6mm wall bottom tubes.
Will fit to my powder coating oven for pre-heating.

Next cutting front and back plates from 10mm plate and injector bases from 50x50x10mm L-bar.

and I still have just a few details to figure out..My design lives...All the time..

Intake build continues.

Pieces are made, beveled then after preheat oven welded. Was heavy to lift to oven, complete jig and all...
Those angles are so that I've place to mount injectors and fuel rails. As was in my CAD (Cardboard Aided Design)
Not gonna weld bungs on it. Just mill spec bore for them.
Never mind the finish of those welds. There is 3 passes.
Main thing is that its over the surface and penetrated.
All will be machined smooth.
Made top plate, first, will not be final one. I can tell you that.

Then we arrive point of my life when I got job at trade school machine shop foreman so now I got tools, a lot of machining machines and full welding shop other side of the hall... You will see that also..

At summer holiday, I reassembled the engine to manual milling machine table and let the chips fly..

Back to this, after talked with Swedes again. Desided that I need to make risers to make room for air. So I machined them. made a step joint so I can be sure they don't move or leak. milled o-ring groove and holes for allen bolts on it.

Next will make mounting face and - plate for the supercharger to be bolted to intake.

looking mighty!

Been awhile.. But be sure project has goon forward.. alot..

Lets continue build this intake. Next task, build intake top plate and to mill recess to it for supercharger mounting plate. Bolts for that can be on the sides, but front and back edges are under the blower. So I milled step edge on those. The plate will lock tight against O-ring when blower is lowered and pushed back. Top plate is bolted with countersink bolts and had to check twice that bolts clear all the rest. A lot of going on here.

Then copied the supercharger mounting bolt pattern and discharge port shape and location and transfer it to mounting plate. Straight, super important thing here.

Finally supercharger is bolted on top of the intake. First time. Now can take it off the engine and take it to our large vertical boring machine to face off front and back faces. With machine that size and options, its easy to do this kind of tasks. Reat time to practice Heidenhain programming..

Same time I started to do next cool parts. Supercharger intake flance. Took photo of the supercharger, imported is as canvas to Fusion360. After drawing it until I was satisfied, then 3d printed it out from PLA, just to veryfy that it will work. Print quality isnt great but dont care, it works. I transfer model to Surfcam and made toolpaths for it and started our Haas mill. Came out awesome. Have super plans how to continue from here. Again, finnish afer machining isnt super great but dont care, it will see some tig-glue so it will get worse before gets much better.

Next to open front and back faces for intercooler fittings. ¨Then need to design, draw and machine a plate to seal everything up.

does anybody like to see more?

Definitely custom!!!!! :thumbsup:

Glad to see you're still working on this and making progress! Thanks for sharing.

Wow!! :hail::hail:

Thx Trey,
Build is away ahead, actually there's like two things that are lacking. Diamond to make my pistons (after 3 orders 2 years of waiting) and me posting here.

Also the lack of comments makes me think that here isnt intress of builds like this.. since this is not a collection of parts from those usual companies.

Lets continue, making the twin throttle body intake elbow for 4.2L, 4.7L and 4.9L Kenne Bell superchargers.

After internet search couldnt find 5" thin wall 90 degree elbow with 1 r (5" this case) radius. So need to make some.

First draw a simple hammer form in Fusion 360, holes at the ends are for vise grips, hold the plane down. Use pieces of rubber hoses at noses of the pliers, dont make the panel.
Then 3D printed it out of plain PLA and started anneailing 2mm aluminium with sharpie and propane torch.
When you have burned the sharpie off, the aluminium is soft. Depends how much you shape it, you may need to redo the annealing.

After shaping with plastic slapper and shrinking I had four halfs done. Time to get them fit the machined flance, used machinest square and laser to determine where to cut the overlapping parts off.

Next task make mounting tool for the flance and bold it tight so it dosent deform under welding. To keep it straight. Tig-welded the halfs together and I also machined flance with O-ring groove for 102mm LS throttle body. Those got welded to open ends of the eblows.

After all was welded, I spend some time to file the seams and slapped them all smooth. I took it to work, machined mounting surface to our vertical milling machine and squared the TB flances, also the special flance in the middle. more that later..

That kind of vertical mill is powerful tool to have. Work area is measured in meters (feets), Table can be turned in one thousands of degree (0.001') or -millimeters. Just get your bearings with 3D measuring tool..
This kind of job is easy for this kind of machine, just turn the table 180 degree and you get both size parallel to each other with same mounting. Or 90 and machine the face of the middle flance. Everything it parallel and square and straight. Even machined the main flance straight as last task with another set up.

So lets get to back the square flance in the middle. I did re-machined that O-ring groove again. Thats how much it shrank in welding.
Anybody want to guess what is for?
Something outside of the box..again..