DIY Intake Spinoff Thread for Sheet Metal Design

6leakertweeker · Mar 1, 2012

Original Redneck 6.0 DIY Intake thread: http://www.powerstrokearmy.com/forums/showthread.php?t=13245

I didn't see why a guy couldn't take a gasket as a pattern and have some 3/8" billet flanges milled then just weld some round tube on top of it. Then cut open the holes in the flanges and grind it for optimal flow.

06f250powerstroke · Mar 1, 2012

altenator bracket is part of manifold

windrunner408 · Mar 1, 2012

Yea but one could easily fab up a new one.

06f250powerstroke · Mar 1, 2012

I dont know about easily or i think it would be done by now. i think its doable

Mwilbur516 · Mar 1, 2012

6leakertweeker said:
I didn't see why a guy couldn't take a gasket as a pattern and have some 3/8" billet flanges milled then just weld some round tube on top of it. Then cut open the holes in the flanges and grind it for optimal flow.

I've stared at my intake several times and wondered the same thing. My problem is, out of all the things I can do well, welding is not one of them. I would never attempt welding aluminum. I keep waiting for someone to post pics of something like this, but it never happens. One day someone with more skills than me will make this happen and pull down some serious money in the process

Powerstroked162 · Mar 1, 2012

Mwilbur516 said:
I've stared at my intake several times and wondered the same thing. My problem is, out of all the things I can do well, welding is not one of them. I would never attempt welding aluminum. I keep waiting for someone to post pics of something like this, but it never happens. One day someone with more skills than me will make this happen and pull down some serious money in the process

Let me know if you're needing a manifold. Our Apex lineup should be done within the next week or two

6leakertweeker · Mar 1, 2012

Im going to think about trying it. I'm thinking 3/8" for the flanges. 1/4 for the brackets. Anybody have any inside diameters of the factory manifold? Would 1 7/8" I.d. round tube be big enough?

I'm going to have to try and get a hold of an extra manifold for measurements and throw some stuff on CAD and see what i can come up with.

Beast6.0 · Mar 2, 2012

06f250powerstroke said:
I dont know about easily or i think it would be done by now. i think its doable

It's already been done a few times, it's not hard at all. Not exactly cheap though.:ford:

06f250powerstroke · Mar 2, 2012

Beast6.0 said:
It's already been done a few times, it's not hard at all. Not exactly cheap though.:ford:

Ive never seen one, maybe on a full out race truck, how about the guy running a stock like set up

dstryr · Mar 2, 2012

06f250powerstroke said:
Ive never seen one, maybe on a full out race truck, how about the guy running a stock like set up

I'm working on one similar in concept for the 6.4s...

Lubbockguy1979 · Mar 2, 2012

just out of curosity is steel out for fear of rust or something? i mean you could have flanges made from gaskets and use square tubing which depending on the wall thickness would be rounded. seems it would be easier.

6leakertweeker · Mar 2, 2012

Lubbockguy1979 said:
just out of curosity is steel out for fear of rust or something? i mean you could have flanges made from gaskets and use square tubing which depending on the wall thickness would be rounded. seems it would be easier.

Nope can't remember who it was but somebody has a black steel one made out of square or rectangular tubing.

Lubbockguy1979 · Mar 2, 2012

I've seen cad drawings and someone started a round tubing manifold that looked like the banks piece. I think it was mpd that was doing it. Never saw the outcome though. Also shawn I though as well as other built a sheet metal intakes a year or so ago but scrapped them for some reason. I just don't remember the reason off hand

Extended Power · Mar 2, 2012

Shawn made a manifold out of 2" x 3" steel.

Redneck6.0L · Mar 2, 2012

He one on my race truck was made from 2x3 square tubing. Had it ceramic coated black so no rusting issues

Beast6.0 · Mar 2, 2012

06f250powerstroke said:
Ive never seen one, maybe on a full out race truck, how about the guy running a stock like set up

My truck's been without the factory Alt. mount for 2+yrs of daily driving and towing. Shawn and Tyler get props for doing it first on Tyler's truck (or at least it was the first time I'd ever seen it). I used a similiar if not the same set-up when I needed a pipe to go were the factory alt. was, to connect my chargers. I have completely shaved the original mounts off my intake, and just use the dual alt. kit available at the Ford dealer. It's not cheap, around $900 for everything if I remember right (maybe more, I can't remember the exact cost for all of it). Best deal is if you come across a salvage motor being parted-out that had the dual alt. option already. Way cheaper.

Hope you're intake turns out well, and performs like your expecting. I'm all for anyone who takes on building their own stuff:rockon:

Mdub707 · Mar 2, 2012

Beast6.0 said:
My truck's been without the factory Alt. mount for 2+yrs of daily driving and towing. Shawn and Tyler get props for doing it first on Tyler's truck (or at least it was the first time I'd ever seen it). I used a similiar if not the same set-up when I needed a pipe to go were the factory alt. was, to connect my chargers. I have completely shaved the original mounts off my intake, and just use the dual alt. kit available at the Ford dealer. It's not cheap, around $900 for everything if I remember right (maybe more, I can't remember the exact cost for all of it). Best deal is if you come across a salvage motor being parted-out that had the dual alt. option already. Way cheaper.

Hope you're intake turns out well, and performs like your expecting. I'm all for anyone who takes on building their own stuff:rockon:

You have pics of this? Luckily, for whatever ungodly reason, my Supercab/shortbed truck came with dual alts...

6leakertweeker · Mar 2, 2012

So I've been playing with idea for a few hours. What do you guys think of a 2 piece manifold? The bottom half would use shorter bolts all in the factory locations and then the top half would bolt to the bottom half using a different bolt pattern and less bolts than the factory design. The factory bolt heads would be inside the intake so to speak. I think this would eliminate the problem of trying to seal around every bolt. The downfall would be designing and obtaining a gasket design that can withstand good pressure between the two intake halves.

6leakertweeker · Mar 2, 2012

That or a design more like an exhaust manifold. If there's enough room you could prob have a main tube with runners extending from the main and bolt the flanges down outside the manifold. Ill have to take a look at a manifold to see if that's possible.