intake manifold

admin

no pics yet, but i'll have them up soon. this is for so im about 90% done with making my intake manifold. it uses a holly flange so i can use it on anything with that syle manifold. basically so you can go from carb to fuel injection easier. i made it out of a sheet of 1/8 inch thick 6061 T-6 aluminum. basic design. but very functional. now a few places  have a 90* edge where the air will be flowing. like this "L".....now, i cant get in there to weld down the edge and grind it out smooth. but i can easily get my hand in there to use a puddy or something similar to smooth out the edge. (think caulk on an edge when sealing a speaker box or similar). so, what puddy to use? i need something that i can lay on smooth like caulk but will harden like JB weld and stay there even with 30psi pushing past it.(turbo) any ideas? experience with this?Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:I wouldn't hesitate to use JB weld. Auto Parts stores also sell two part hi-temp quick set epoxies that work extremely well at holding onto metal and are pretty pliable.
Reply:I'll wait for the pics.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Uh what ?John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:heres a few pics...now this is my first time doing aluminum. soooo....beware i dont know if i trust JB weld. i have used it quite a few times. but if it was to come loose, that 2 dollar stick ruins a few thousand dollars worth of building... Attached ImagesLincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:You don't need to weld on the inside and outside. I would probably grind down all those welds and go over them again.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Looks plenty flowey to me...There is a nice bend along the back and the edge at the beginning corner is no biggie..Just file radious the sharp edge inside and let the air flow.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:The proper way to fix that back portion and your sides would be to take an aluminum dremmel and mildly port those areas for proper flow into the intake tract.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:That does not look bad for a first time.I wouldn't use jbweld either. I really despise the stuff.I really think that if you got it sealed good from the outside it would be fine.
Reply:im not worried about sealing it. i know theres no leaks anywhere. and i started grinding down the welds. and i am currently porting the holley flange smooth for better flow. its just not done yet, i plan on going over the edges, now that my aluminum skills are getting better. it will mainly be a for cosmetics. and im not worried about having enough flow. its got to be smooth tranfers. uneven edges and abrubt sufaces can hurt performance. its not always about how much air gets to the motor. but also how it gets there.oh yeah...and welding an 1/8 inch thick t-6 aluminum to a 1 1/2 inch cast piece for your first time can be tricky...lolim learning a lot here. i cut these things out with a crappy cut wheel. and the bends it at came from me tacking the piece in place then standing on top of it so it would lay down. seriously...i was standing on top of this manifold and welded the top to the sides. lol...what a rookie. a later used a press to hold the bottom flush...Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Any recommendations/suggestions on welding cast aluminum to 6061?  I'm just about to do that because I had to chop the intake head flange off an old manifold to make a new one with individual throttles.
Reply:Good for a first try.  Now practice your welding and try again. DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:well, im no one to be giving tip on welding...since im still a rookie. but i just started my weld on the cast first so it could take up more heat.  since it was so much thicker than the t6 aluminum. what car you making it for? what throttle bodys? im going to to the same using gsxr throttle bodies...Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:You could stick it in a saw and make it straight across the frontDewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Originally Posted by sen2twoim not worried about sealing it. i know theres no leaks anywhere.
Reply:i didnt do a "real" pressure test cause i dont have the equipment. but i did put it in the dark and shine a light into it to see it there were any sources where it could get through. not the best way to test, but it does work pretty well. light can get through areas where even soapy water can not.Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Originally Posted by sen2twoi didnt do a "real" pressure test cause i dont have the equipment. but i did put it in the dark and shine a light into it to see it there were any sources where it could get through. not the best way to test, but it does work pretty well. light can get through areas where even soapy water can not.
Reply:yes i do know what you meant. i tested for boost leaks and gasket leaks that same way before when i worked in a shop. and although i am a rookie to aluminum. i know how to tell if theres complete penetration in my welds. welds do not need to look pretty, to be strong or to get full penetration. most of the welds are grinded all the way down now so it looks like the manifold was formed that way, not cut and welded. this is why im pretty damn sure theres no leaks also... im not trying to argue. and this is off topic.has anyone used Devcon here? we use it in rx7s (or other rotary engine cars) to fill intake ports up and re-shape them. but i dont know how well it bonds or "sticks" to aluminum.Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Sorry bud, but I call NG on your welds for being even strong or being leak free just by what they look like. Call me out, but I tell you like I see it. You need more practice and seat time behind the mask for aluminum my friend even before attempting to make any type intake part. Vacuum leaks later on when tuning is like chasing your tail.  We are here to help, but a lot of rookies come in here and say hey look at this. They get an honest opionion from skilled people (I am not saying I am super skilled but I know I am humbled when I pressure check my welds that require it) and some take offense to it where they "think" they know the answers even before they post. I do not see any of your machine settings or even what machine you used..etc.Maybe off topic, but I doubt it. You posted a picture of your poject in the Welding and Projects forum. No matter what, off topic or not, it will get critiqued, regardless of what question was asked relevant or not.  T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Originally Posted by sen2twowell, im no one to be giving tip on welding...since im still a rookie. but i just started my weld on the cast first so it could take up more heat.  since it was so much thicker than the t6 aluminum. what car you making it for? what throttle bodys? im going to to the same using gsxr throttle bodies...
Reply:nice set up...i have a set of ITB's from the 20v too. i was going to use them cause i got them for free from my brother. but i decided to go with the GSXR ones. the set up is a little nicer. good luck...post picks when your done...Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Haha, I'd like to see pics of yours as well.  I was originally going to use a set of throttles off of a gsxr 600 but I decided against the couplers and clamps, I want a cleaner bolted look.