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Old 03-26-2010, 01:09 PM   #1
neversummer489
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Default Post your custom intake manifold

I was looking at the "post your beads" thread here and saw a couple of custome (one off?) intake manis. Any info on the gains of the manifolds would be cool too.
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Old 03-30-2010, 02:41 PM   #2
PrecisionCustom
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Just a quickieee for ya


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Old 04-01-2010, 08:09 PM   #3
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i noticed those pictures too, on post your beads..

I have lots of questions about why and how this is done.. I'm nowhere near a good enough welder to do it... but I'm definitely gonna keep an eye out and watch this thread grow

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Old 04-01-2010, 09:18 PM   #4
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PrecisionCustom... that looks nice! you got anymore pics?
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Old 04-02-2010, 09:25 AM   #5
Patrick Olsen
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There are a bunch of fabricated intake manifolds (some from tuner shops, some from "amateurs") in this thread. Can definitely give you some ideas.
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Old 04-05-2010, 09:39 PM   #6
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Sweet thanks
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Old 04-05-2010, 10:04 PM   #7
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Ill post some tomorrow. I have made about 10 of these in my day. Each for subbys. All have seen 20-38psi and never failed. Had some issues at first with cylinders running to lean, but have further fixed the problem. If you got questions about this setup Pm me and I can help ya out.
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Old 04-06-2010, 01:49 AM   #8
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I'm looking foreward to seeing this
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Old 04-07-2010, 10:47 PM   #9
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P custom. I want to see the final product looks good.
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Old 04-08-2010, 02:59 PM   #10
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I know many of you seen this manifold already but here's a bit more in depth of how it all went down. Enjoy!









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Old 04-08-2010, 11:39 PM   #11
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what kind of gains are you seeing with that kind of intake manifold scubydrew?
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Old 04-09-2010, 06:01 PM   #12
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I'm not sure the exact number but I wanna say it was between 15 and 20 wheel horsepower. Call the shop they have record of that kinda stuff. I just make the parts. lol
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Old 04-09-2010, 06:36 PM   #13
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very pretty manifold..
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Old 04-09-2010, 10:24 PM   #14
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I probably couldn't afford the thing anyway, just curious if you knew
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Old 04-11-2010, 01:32 PM   #15
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P custom. What are the costs associated with you setups???
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Old 04-13-2010, 06:44 AM   #16
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I fiddle about with manifolds a bit just for welding practice. Made this for an EJ25/35R we built. A friend had built one similiar using round tube that flowed well but was very complex and had a heap of welds so i though I'd do one out of box so there would be limited welds, greater strength and a bit more volume. The runners are early EJ25 quadcam which are basically straighter versions of early EJ20G runners. I never had it flow tested due to time constraints, would have been interesting to compare.





The main reason I do the manifolds is to reposition the throttle body to the front. The main reason for this is to free up room at the rear for bigger turbos as in RHD cars we are struggling for space.
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Old 04-13-2010, 09:26 AM   #17
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looks real nice man
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Old 05-01-2010, 06:43 PM   #18
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EZ30D manifold modified for an EZ30R turbo. Had heaps of trouble with the cast when welding it, couldn't get it clean. Any pros know how to prepare castings for welding?









For this, not fitted yet because the owner is a slackass.

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Old 05-01-2010, 07:29 PM   #19
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Is that a ford iac?
Quote:
Originally Posted by jzk25 View Post
I fiddle about with manifolds a bit just for welding practice. Made this for an EJ25/35R we built. A friend had built one similiar using round tube that flowed well but was very complex and had a heap of welds so i though I'd do one out of box so there would be limited welds, greater strength and a bit more volume. The runners are early EJ25 quadcam which are basically straighter versions of early EJ20G runners. I never had it flow tested due to time constraints, would have been interesting to compare.





The main reason I do the manifolds is to reposition the throttle body to the front. The main reason for this is to free up room at the rear for bigger turbos as in RHD cars we are struggling for space.
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Old 05-01-2010, 10:32 PM   #20
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It's a ford throttle body from an Australian Ford Falcon 4l six. They are cheap and have built in 2 wire IAC so we often use them.
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Old 05-02-2010, 07:31 AM   #21
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Quote:
Originally Posted by jzk25 View Post
EZ30D manifold modified for an EZ30R turbo. Had heaps of trouble with the cast when welding it, couldn't get it clean. Any pros know how to prepare castings for welding?
Have a chat to the guys at HPC at Brendale. If they can get the oil and containments out of a casting well enough to ceramic coat, it should be fine to weld.

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Old 05-03-2010, 02:43 PM   #22
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Quote:
Originally Posted by jzk25 View Post
EZ30D manifold modified for an EZ30R turbo. Had heaps of trouble with the cast when welding it, couldn't get it clean. Any pros know how to prepare castings for welding?
Do cleaning passes with the welder. Set your amps just high enough to melt the surface of the metal and set the cleaning percent fairly high. Just go over all the edges where you are going to weld. Let the surface get molten, and watch the crud float to the top and edges of the puddle. Then go over it with a carbide burr or something to clean all the crud off. Then do another pass or two until you don't see as much crud in the puddle. After the last pass just wire brush it very well and clean it with acetone, don't use the carbide burr. It will weld 100 times better.

If the casting has a lot of oil in it you can heat it up first to burn off all the oil. A random old oven works well. Crank the thing to 375*F or so and put the casting in there for 15min to an hour depending on how thick it is. Don't use the oven you bake cookies and what not in. At least I wouldn't do it. I don't like the taste of 10W30 in my chocolate chips. You can also use a torch to do the same thing but be careful not to overheat it. I'd use a temperature indicating marker or something.
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Old 05-03-2010, 03:26 PM   #23
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Quote:
Originally Posted by FourOnTheFloor65 View Post
Do cleaning passes with the welder. Set your amps just high enough to melt the surface of the metal and set the cleaning percent fairly high. Just go over all the edges where you are going to weld. Let the surface get molten, and watch the crud float to the top and edges of the puddle. Then go over it with a carbide burr or something to clean all the crud off. Then do another pass or two until you don't see as much crud in the puddle. After the last pass just wire brush it very well and clean it with acetone, don't use the carbide burr. It will weld 100 times better.

If the casting has a lot of oil in it you can heat it up first to burn off all the oil. A random old oven works well. Crank the thing to 375*F or so and put the casting in there for 15min to an hour depending on how thick it is. Don't use the oven you bake cookies and what not in. At least I wouldn't do it. I don't like the taste of 10W30 in my chocolate chips. You can also use a torch to do the same thing but be careful not to overheat it. I'd use a temperature indicating marker or something.




^ I second the above operation
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Old 05-03-2010, 03:55 PM   #24
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I was gonna ask how well the cast bits welded to the sheet aluminum.....I've got some pieces parts layin around that could be fabbed up into something cool. For now I'll just whore out the oft-used pic of the Irish Mike's manifold on our 98RS.

If my memory serves, it's 3.5l in volume and uses runners grafted from an Benz SL something or other....


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Old 05-03-2010, 06:13 PM   #25
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beautiful work everyone.. It's very interesting to see the amount of originality floating around.. very refreshing to see.
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