News

JBS K03

Now that we have received our first pre-production sample we have started testing procedures.

Initially we have flow bench tested against a standard OEM K03 manifold.

The testing was carried out on a Superflow SF-120 Flow bench, which is an industry favoured bench for testing engines up to 100 Hp (75 kW) per cylinder.

The SF-120 has built in flow bench swirl meter, 4 valve universal opener with dial gauge, exhaust velocity pitot tube, inlet velocity pitot tube and specific cylinder head adaptor, making it the ideal machine to test our new manifold designs.

The manifolds were tested on the flow bench with a AUQ 1.8 20v turbo head with no valves. To keep the flow data accurate for each runner the flow was simulated with the appropriate head valves open and closed.

The flow was tested through the most optimum runner, which is usually the longest (for the K03 this is runner 1) and through the shortest runner (runner 3 on both manifolds). Using these 2 runners shows the flow range of the manifold and gives the most usable results.

Results

Test Data:
Head: AUQ 5v
Depression: 10" @ 12 deg C temp correction
K03 OEM Cast Manifold

Conclusion

JBS Developments main aim when starting to develop the new K03 upgrade manifold was to produce a manifold that not only performed better than anything else on the market but that was also more reliable.

From the results it's clear that in ideal conditions the JBS K03 Cast manifold gives a 50% flow increase in CFM throughout the runners.

Developing an upgrade manifold for the K03 is not only about high flow and big power figures, but about how the manifold reacts to the environment. Performance manifolds tend to crack due to weak materials and the stress the manifolds are under due to high exhaust gas temperatures caused by poor design.

So with hours spent in CFD analysis on individual runner balance and flow to ensure the flow of the exhaust gas doesn't affect the manifolds structure along with extensive research into the latest high temperature resistant cast irons to combat the high exhaust gas temperatures. The new upgrade manifold will be more reliable and more efficient whilst being able to withstand high exhaust gas temperatures means that higher boost levels will be achievable, it also means that due to better flow properties the manifold will have lower EGT's and therefore be more reliable.

The next set of tests to be carried out will be on the rolling road with a standard K03 turbo and a hybrid, so we can see the overall increase in boost, EGT's and spool times, as well as see the true top end capabilities of the manifold.