Custom intake manifold.

BURT150

Im curently making up a new inlet manifold and thought id post some of my progress.

All the parts so far are hand made and iv port matched the flange to my new head 🙂

Also worked the egr hole blank into the end of it.

Heres a couple of pics of the runners and plenum ill be using:

Pics show the angle of the runners wich im not really happy with but cant be avoided due to the spaces in the engine bay and the fact of keeping the air box in the original position.

Iv been making slow progress with it but now that work has cut my hours to a 3 8hr day week(wankers :evil: ) it looks like ill have a bit more time on my hands.

pottsey

looking good burt ,is this a one off or are there gonna be more :thumbup:

MikeS

hey we talking about burt here lol

this man will have a catalogue out soon 🙂

BURT150

pottsey said:
looking good burt ,is this a one off or are there gonna be more :thumbup:

Id like to make a few of them but it'l be a little while before its finished and tested but if it proves to work wich it should ill make some more :thumbup:

MikeS said:
hey we talking about burt here lol

this man will have a catalogue out soon 🙂

Ill get there one day mike :lol:

pottsey

nice one burt look forward to seeing the finished product ,stick me on your list i'll be your first buyer :thumbup:

BURT150

pottsey said:
nice one burt look forward to seeing the finished product ,stick me on your list i'll be your first buyer :thumbup:

No worrys :thumbup:

sdbutler10

looks good burt, hope this working out for you.

cavaddict

Looking good Burt 😃 Wish i'd made mine manually now....would have been done!! Had most of it wire eroded but still had to finish part by hand as the machine kept conking out. Also found out that our brilliant drawing office has put all the ports 1.5mm too high in the cnc program dunno.. . Still, will be taken care of by the porting. Will bung some pics on the ATOM X inlet post later.
Will be watching this to see if you have any probs....save me making them heh heh heh :angel:

BURT150

cavaddict said:
Looking good Burt 😃 Wish i'd made mine manually now....would have been done!! Had most of it wire eroded but still had to finish part by hand as the machine kept conking out. Also found out that our brilliant drawing office has put all the ports 1.5mm too high in the cnc program dunno.. . Still, will be taken care of by the porting. Will bung some pics on the ATOM X inlet post later.
Will be watching this to see if you have any probs....save me making them heh heh heh :angel:

Thanks. I took some hours chain drilling it and filing it out by hand but got there in the end :roll:

One mistake i made so far is one of my runners is cracked down all 4 sides after squashing it to the port shape. Not a problem tho as ill just run a weld up it.

If you going to use 12or 10 guage tube remember to anneal it first that way it'l flatten without cracking.

And that runner ends up under the ecu anyway so it wont be seen! :wink:

Ill post some more progress in a bit :thumbup:

BURT150

Ok heres a few more pics, I tacked the runners on today and tonight iv got the holes cut into the plenum ready for welding 🙂

The plenum is a bit of 4 1/2 inch tube cut nearly all the way down the middle. I wanted to leave it open so i can weld around the runners on the inside to create a kind of bell mouth on them to help the flow a bit.

So its now looking like something an ready for me to get tigin.

Also need to sort out a take off for the oil breather. I know they get covered up with the sc manifold without problems but for the sake of taping a fitting into the manifold flage i'd just as well do it.

MikeS

dont forget brake booster and evap valve 🙂

BURT150

MikeS said:
dont forget brake booster and evap valve 🙂

Thats still yet to come mike. once the cover is on the plenum ill weld a plate on underneath it and use some pipe fitting for take offs for all the vacumes and brake servo :thumbup:

BURT150

Bit more progress, I found a man size bit of steel in the garage to use for building and welding my maninfold on.

Aly pulls quite a bit when welding so hopefully this will help keep everything nice and strait.

Also got it dry fitted to work out T/B position and to see how everything will fit around it. Its all a bit tight so its looking like im going to have to relocate the ECU and extend a few cables and also mod the coolant pipe slightly to give it some room.

Other than that its going well 😃

sdbutler10

thats some great progress burt, im loking forwad to seeing this done, great workman ship, wish i could tig 🙁
hope this works out for you mate.

Sjdickso

As said some great as always Burt! lets hope it brings a good gain your way.

BURT150

sdbutler10 said:
thats some great progress burt, im loking forwad to seeing this done, great workman ship, wish i could tig 🙁
hope this works out for you mate.

Thanks mate, Should look good when done. It's a shame tig's are stupid money else i would of had my own by now :lol:

Im just lucky work lets me use theres.

Sjdickso said:
As said some great as always Burt! lets hope it brings a good gain your way.

Thanks si. The plan is to see what my car is putting out atm at the up coming rolling road day, then ill fit it after and get another power run to get an acurate figure of the increase if theres any dunno..

Wiswion

great work bud... keep it up

Oh Burt btw
tig welders aren't that expensive (well over this side of the ocean lol) and tig is relatively easy compared to mig and old fashion welding styles

BURT150

Wiswion said:
great work bud... keep it up

Oh Burt btw
tig welders aren't that expensive (well over this side of the ocean lol) and tig is relatively easy compared to mig and old fashion welding styles

Thanks mate.

You guys got it good then. a good ac dc tig over here is at least 1800 pounds :wtf:

I wouldn't say tig is easyer than mig.

Wiswion

i started looking @ tig welders a year ago maybe and found a decent (not the right one that will do everything perfectly, but just ok) for about 300$ lol
i say easier cause tig is cleaner and can work tig without any kind of heat protection... only your mask and your set

BURT150

Bit more progress.

Mostly welded up or the main parts at least. Was a bit of a job to get the heat in it after bolting it down on the steel block but wound the tig up to 240amps and gave it maximum attack!

Just gotta spend some time on cleaning up the openings of the runners then ill weld the lot up.