My Custom Intake Manifold

[06f250powerstroke]

Im not surehow to post pictures but hopefully you guys can see them, I wanted to build something with minamal welding on it for reliability. So far I have cut the posts out and cleaned up alot of excess aluminum that will be restricting flow, along with smoothing out the casting on the intake holes, So far this is what I have started, I will post up more pics as i progress with this

 

[Pizza pig]

nice man, this is what I was going to do to a spare manifold as well. I dont like the idea of cutting the whole top off, I think it would be easier to weld up each little whole like they do on the 6.4 manifolds. Let us know how it works out for you

 

[Agjake11]

In to see this one through as I also have a spare intake

 

[smokinstroker]

are you forgeting about the aluminum thats runs between each of those posts.

 

[06f250powerstroke]

you mean around the intake holes?

 

[smokinstroker]

No, between the posts that you just drilled out there are alluminum pieces that connect each post.

 

[06f250powerstroke]

thats a ridge on the top of the manifold inside,

 

[smokinstroker]

let me see if i can dig up the pictures from when i did mine.

when i milled the top off there were some pretty large pieces of aluminum running the length of the manifold. if i remember correctly they connected to those posts.

this is taken from dougs photos.

 

[Mdub707]

There's a reason Doug was machining the whole top off... there is a lot of stuff inside still restricting flow.

Nice to see a few different approaches though.

 

[06f250powerstroke]

those pieces you see there connecting the post are part of the top portion of the manifold, When you cut the top off you just cut that ridge in half, on mine i just drilled out the posts and left thoses ridges as they run the same way as air flow going into the motor. i dont see how they can be restrictive as they are not blocking the path of air flow

 

[windrunner408]

Looks good man. If a manifold is modified this way, how are the holes typically plugged?? How do you plan to do it?? I am curious to know what performance gains you notice.

 

[06f250powerstroke]

Im using aluminum washers 1/4 thick an tiging them around the opening then tapping them with a tappered tap so the plug will tighen up

 

[windrunner408]

Got ya. Sounds good. Hope it works out for ya.

 

[DZL JIM]

Im using aluminum washers 1/4 thick an tiging them around the opening then tapping them with a tappered tap so the plug will tighen up

So, you'll drop the moutning bolt in through the washer's hole and tighten the intake on the bottom plane, then plug the hole with an NPT plug? So the mount bolts aren't trying to squish the intake box anymore.
Correct?

 

[06f250powerstroke]

yes thats the plan, might have to make some adjustments hear and there but i think its going to work pretty well

 

[Pizza pig]

yup thats really the only way to do it. What about using a ORB plug fitting so that its sealed completely?

 

[windrunner408]

that's exactly what I was wondering.

 

[06f250powerstroke]

whats an ORB plug fitting?

 

[Pizza pig]

its like what fuel pumps use for fittings, its just a normal plug but it has an o-ring on it to seal it, theyre awesome and that would work really well I feel like so you could bolt the manifold down from the inside, then use your welded washer idea, tap for threads and thread these in to plug the hole, then you wouldnt really need to worry about crush washers.

 

[07_powerstroke]

I really like how you plan to do this, nice work!