Sheetmetal Aluminum Intake Welded to Cast runners

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Hey guys,I kind of a newbie to TIG welding, see my intro thread from a few weeks back (http://weldingweb.com/vbb/showthread.php?t=63432)I've been learning to TIG aluminum with our old Hobart TR-301. The work primarily supports my car hobby (see above intro thread).This week I got some work done on my new intake manifold design.  The manifold started out as a cast plenum from a Nissan Pathfinder. Its a good OEM design, but the inlet faced the wrong direction and the volume is a bit small for my application.  This is a generic picture of what the OEM intake looks like. I bought mine from the junkyard for $40 and bead blasted it.I started by sectioning the plenum and welding on a .25" aluminum plate. I preheated the cast runners to 400°C and welded my aluminum plate on the inside of the ports.  For welding to the cast, I used a 3/32" orange tungsten, 3/32" filler, and the machine set to about 300amps. I probably shouldve used 1/8" tungsten, because the 3/32 was burning off at these amperages.I proceeded to port the plate out using a die grinder, carbide bits, and some cartridge rolls.I also welded the outside of the plenum (which was considerably more difficult). I smoothed the welds out for a better look:From here I sectioned a 4" mandrel U-bend of aluminum (about .125" thick). tacked this on, then cut out the top and bottom pieces (.125" thick) using a jig saw.I welded the inside of the base as well to get a bit more strength:Here is an installed picture.  I am awaiting a new Throttle body to finish off the project.Now, on to the critique.  This was my first experience trying to make long seamless passes. I am not good enough at "reloading" the rod in my hand, so I had to stop or dwell to shuffle the filler. I definately need to work on this. Thinking of sitting in front of the TV and just shuffling rod for practice. Second problem was that I dab too much for the inches travelled. I think I need to weld faster (more heat obviously) and dab less/inch.  Thanks for reading. Let me know what I should work on.I'm sorry the pictures aren't the best. I will try to take some with a real camera (not phone) and get them uploaded...Last edited by Mike_GruiZinga; 01-08-2012 at 04:36 PM.
Reply:Check the .25 AL plate for flatness with good straightedge.More than likely it will need surfacing. I'd surface itas a matter of course.Blackbird
Reply:Originally Posted by dave powelsonCheck the .25 AL plate for flatness with good straightedge.More than likely it will need surfacing. I'd surface itas a matter of course.
Reply:Nice job so far. You vg doesn't look like it will have any problems breathing. I can't wait to see the finished project.
Reply:looks pretty fair so far. smooth even welds take practice and time under the hood. Looks like a great project. IF FAT BASTARD RUNS FOR PRESIDENT HE'S GOT MY VOTE.
Reply:I like it very crafty!
Reply:Nice work, kudo's on just getting in there and getting it done.