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mrturrari · 07-09-2009, 02:58 AM

It's been over 6 months since I started working on this but it is finally to a point where I am thinking it actually might work.

I was a little worried the material was going to be too thin (0.060") to get good welds but my friend who did all the welding had very little trouble with it. He has a very nice tig setup and lots of experience with aluminum.

The runners are 11.25" long (14.25" to the valve) and 2" OD mandrel bent tubing cut and bent to taper down to the port. The runners go from 2" at the velocity stacks down to a little under 1-3/4" at the flange and it works out to be about a 2 degree taper. The plenum is about 3 liters and will have a gen3 3sgte TB attached to it once I figure out what angle it should be in the car. So I still have do final test fitting to place that and add some thicker plates for tapping in vacuum lines and throttle linkage but it is 90% done.

I can't find any of my pics from earlier in the building of it but here are some from when I finally had all the peices assembled with masking tape:

Getting the runners to fit through the holes after welding them together:

Velocity stacks needed a little help getting to the same height before tacking them in place:

Here it is all done except for the TB flange, vacuum ports and throttle linkage:

And lastly side by side with a stock manifold:

07-09-2009, 02:58 AM	#1 (permalink)
mrturrari I <3 my 5sfe Join Date: Mar 2005 Location: Salt Lake City, Utah Posts: 655 Thanks: 2 Thanked 170 Times in 113 Posts iTrader Rating: (0/0% )	Building my own intake manifold It's been over 6 months since I started working on this but it is finally to a point where I am thinking it actually might work. I was a little worried the material was going to be too thin (0.060") to get good welds but my friend who did all the welding had very little trouble with it. He has a very nice tig setup and lots of experience with aluminum. The runners are 11.25" long (14.25" to the valve) and 2" OD mandrel bent tubing cut and bent to taper down to the port. The runners go from 2" at the velocity stacks down to a little under 1-3/4" at the flange and it works out to be about a 2 degree taper. The plenum is about 3 liters and will have a gen3 3sgte TB attached to it once I figure out what angle it should be in the car. So I still have do final test fitting to place that and add some thicker plates for tapping in vacuum lines and throttle linkage but it is 90% done. I can't find any of my pics from earlier in the building of it but here are some from when I finally had all the peices assembled with masking tape: Getting the runners to fit through the holes after welding them together: Velocity stacks needed a little help getting to the same height before tacking them in place: Here it is all done except for the TB flange, vacuum ports and throttle linkage: And lastly side by side with a stock manifold: