E63 Billet inlet manifolds (W213)

M177 LS2 BILLET INLET MANIFOLDS

MANIFOLD CONSTRUCTION

The factory manifolds are constructed from plastic, in 2 halves and then plastic welded (melted) together) This construction method is economical for large scale production, and (mostly) ok for standard engine power. However, the limits of the factory manifolds are well documented...

Furthermore, the plastic is not able to be drilled or tapped, so optional ports for nitrous, meth, or boost sense cannot be added. Finally, there is no way to add extra port injectors to the plastic manifolds, limiting fueling options. 

ZAC Motorsport engineers researched several construction methods:

1) Casting

+ cheaper to produce
+ able to be produced as a single piece

- Inferior strength (material selection, porosity, hot spots)
- questionable finish 
- low accuracy
- requires post processing (machining)

2) 3D Printed metal

+ able to be produced as a single piece
+ great surface finish

- expensive to produce
- slow construction process
- limited production facilities worldwide
- requires post processing (machining)

3) Billet Machining

+ extremely strong material
+ great surface finish
+ relatively common manufacturing process
+ extremely accurate

- requires 2 piece construction

We settled on machining billet 6061-t6 aluminum. Whilst casting would have saved us costs (1/3rd the cost to produce). The quality of the end product does not meet our standard. Additionally, machining allows us the ability to make incremental changes, or small batch runs with specific customizations (different size port injectors for example), whereas casting requires an investment of a mold, that cannot be changed. All manifolds from ZAC Motorsport are machined therefor, then TIG welded, by our master craftsman right here in Australia.

Optional Port Injection

As emissions regulations get tighter and tighter, manufacturers have had to develop technology to meet the stringent emissions targets. Direct injection (DI) is one of the results. With Mercedes opting for pure DI setup, as opposed to VW group using a combination of port and DI. Our port injection option retrofits to offer similar flexibility and tuning options (when coupled with a Piggyback ECU) as the VW/Audi systems.

The benefits of Port Injection:

• Increased fuel capacity
• Port cleaning effects of fuel into the intake runners, reducing carbon buildup in the ports and on the back of the inlet valves.
• IAT cooling into the combustion chamber 
• Ability to run full E85 fuel.