July 22, 2022
Description
This is a throttle body adapter and intake tube system for the Kenne Bell 2.6L supercharger kit for 2005 - 2010 Mustang GTs. (It might fit other models too)
I had a lot of problems with the throttle body that came with their Stage 2 kit. (130mm single blade) The supercharger mounting plate for the throttle body is too close to mount a standard GT500 throttle body. I chose the FRPP CobraJet Twin 65mm
File TB_adapter16.stl is the adapter for this. It bends and rotates the mounting surface to add sufficient clearance to mount a larger throttle body.
Extra parts you'll need for this:
I chose to print all of these parts with Polymaker nylon PA6-GF for the extra temperature resistance. But you might be able to get by with something cheaper like PETG. It all depends on where you live and how hot your engine bay is. Most vehicles are designed to stay under 212F to avoid boiling the windshield washer fluid.
The TB adapter has a peg on the bottom that lines up with the Kenne Bell fuel rail mounting strap. The purpose of this design is to provide a rest on the center of the adapter to reduce the weight on the 4 screws on the supercharger flange. I've purposely left about 1/4" of space between this peg and the fuel rail. Glue a cut piece of rubber or whatever you can find to fill the gap. I didn't want the 3D print to rest directly on this surface.
The throttle body bolts directly to the adapter with a GT500 gasket. Tap M6-1.0mm threads into the adapter. If it feels like the threads won't hold, get a longer M6 bolt and add nuts to the back side. When bolting to the supercharger, add M6 washers to spread the force over a wider surface area of the nylon.
After the throttle body, print each of the intake tube parts and glue them together with two part epoxy. The tabs should help line them up into the sockets, but they can be a bit of a pain. Depending on how the print turned out, you might need to clean off extra gook from the tabs in order to get a clean fit.
The intake tube is designed to fit directly into the Kenne Bell flexible hose that proceeds to the MAF housing and air filter under the front bumper. On the bottom side of the middle_outlet8.stl file, there are bungs to thread in the PCV line, and an intake air temp probe. If you have a different setup, just load up FreeCAD and delete these objects, then export a new STL file.
I've provided my FreeCAD files for anyone to modify and tweak this to your own needs. The TB_adapter file is hopefully segregated into enough body groups to adjust the flange mounts for any kind of throttle body or supercharger.
The photo I provided from my own setup is still in the prototyping phase. I attempted to electroplate the TB adapter, and that didn't turn out very well. I plan to prime, sand, and paint the intake tube.
License:
GNU - GPL
calh
