build your own modified intake manifold

[chappy]

I've been thinking of doing this myself for weeks. I am not going to spend that kind of money for one. I was also planning a band saw and sawing off the top . I had no Idea what it looked like inside so I was planning on grinding down whatever's inside with a nibbled bit on a die grinder. Now i know and this looks easier with my drill press. I was planning on just reusing the top I cut off and welding it back on. Any reason why you are using a new stock of aluminum instead? I haven't been able to think of a reason not to reuse yet.

 

[smokinstroker]

i have 2 manifold sitting around if someones looking to buy and tackle the project themselves.

 

[chappy]

Shoot me a price please or what you had in mind.

 

[Pizza pig]

yup i have three on the shelf as well :rockon:

 

[FX4 F2-Fifty]

I've been thinking of doing this myself for weeks. I am not going to spend that kind of money for one. I was also planning a band saw and sawing off the top . I had no Idea what it looked like inside so I was planning on grinding down whatever's inside with a nibbled bit on a die grinder. Now i know and this looks easier with my drill press. I was planning on just reusing the top I cut off and welding it back on. Any reason why you are using a new stock of aluminum instead? I haven't been able to think of a reason not to reuse yet.

Im thinking about doing this as well. And as using new aluminum i would imagine since the runners are cut out it would not be near as strong if you reused the original top. 1/4 Aluminum is A LOT stronger than the factory Cast Aluminum.

Now to find someone that will weld Cast Aluminum... I had a difficult time finding a place to weld Cast Aluminum when i did my EGR delete and they have since closed down. Be prepared to pay some bucks to have someone weld and pressure test one.

 

[hawgdoctor]

Im thinking about doing this as well. And as using new aluminum i would imagine since the runners are cut out it would not be near as strong if you reused the original top. 1/4 Aluminum is A LOT stronger than the factory Cast Aluminum.

Now to find someone that will weld Cast Aluminum... I had a difficult time finding a place to weld Cast Aluminum when i did my EGR delete and they have since closed down. Be prepared to pay some bucks to have someone weld and pressure test one.

Bring it on. To bad you're not closer.....

 

[AKHILF]

I think im also going to try this out. Projects like these are fun. So you cut the top off on the sides but you leave the back alone? Or were these pictures taken before you cut the back off? Or is the back not needed to be cut off because you can get a grinder in there and clean it up pretty good? I can get me hands on a mill too. If I do this I run a plasma table all day and i'm sure I can cad up a top plate and burn a couple out of aluminum.

 

[Agjake11]

great thread so far im interested to see it all done

 

[06f250powerstroke]

only problem i have had when i did this is if your using the stock bolts is it may leak around the bolt between the head and bottom of the manifold. the stock gasket is not designed to seal around the bolt. thats the reason elite and go go use small bolts inside the manifold.

 

[wetnsloppy4x]

Im thinking about doing this as well. And as using new aluminum i would imagine since the runners are cut out it would not be near as strong if you reused the original top. 1/4 Aluminum is A LOT stronger than the factory Cast Aluminum.

Now to find someone that will weld Cast Aluminum... I had a difficult time finding a place to weld Cast Aluminum when i did my EGR delete and they have since closed down. Be prepared to pay some bucks to have someone weld and pressure test one.

You just touched on another genuine concern about welding on these intakes. The porosity of the cast aluminum makes it a bitch to get clean enough for an acceptable weld. I could see the plate being an advantage here as thats less material you have to worry about getting soot, oil, and grime leached out of before the welding process.

only problem i have had when i did this is if your using the stock bolts is it may leak around the bolt between the head and bottom of the manifold. the stock gasket is not designed to seal around the bolt. thats the reason elite and go go use small bolts inside the manifold.

Good point. Like Shawn said, use copper washers on top of the plate but how and the heck do you reliably seal up the underside bolt holes?

 

[chappy]

I could see the cast top being a little harder to weld but I've got a good shop that do it no prob. They welded up a 20 in cast alluminum rim for me that got a big rock stuck between the inside wheel an rotor. Punched a big hole and crack right thru the wheel. Held just fine so I see no problem with a air intake. I guess I have to see how thick the casting is and figure out how to seal around the bolt on the bottom

 

[FX4 F2-Fifty]

Also have to consider that cast aluminum its more brittle and there is nothing between the top and bottom of the manifold like there was before. thicker plate aluminum would distribute the load a lot better.

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[El chupacabra]

Would it be possible to weld one totally out of sheet aluminum?

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[chappy]

Also have to consider that cast aluminum its more brittle and there is nothing between the top and bottom of the manifold like there was before. thicker plate aluminum would distribute the load a lot better.

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Yeh I thought of that but they get torques at such a low amount I still don't think it would be a problem unless the casting is super thin. I think I'll still use a new piece of solid aluminum on top.

 

[FX4 F2-Fifty]

Yeh I thought of that but they get torques at such a low amount I still don't think it would be a problem unless the casting is super thin.

True, but with all the vibration, heat, and boost I just think it would be worth it to put plate on there while it is out. The plate its the cheap part compared to the cost of getting it welded. Unless you know someone personally. I am curious to see what they come up with to seal the bottom.

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[Hotrodtractor]

Would it be possible to weld one totally out of sheet aluminum?

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Anything is possible.

 

[Sequential6.4L]

anyone got an intake manifold for a 6.4L? very interested.

 

[Beast6.0]

Thanks for posting those pics, and for the tip on sealing the top Shawn. Always appreciate the advice.:ford:

i have 2 manifold sitting around if someones looking to buy and tackle the project themselves.

Save one of those for me if you don't mind, Chris. I'll try to remember to ask you how much you'll take for it next time I talk to you.

Thanks,
Lonny

 

[SSpeeDEMONSS]

Since I have 2 manifolds, maybe this could be something I could play with too. My friend could do the welding too.

Garrett

Probably getting paid at work to post this from my D1

 

[smokinstroker]

We need to take a look at how that bottom can deal, I may have a boost leak there, never checked.

On the other hand, take a look at an intake manifold gasket, I'm pretty sure it has the sealing material around where the bolt goes.