For those wanting to build their own intake manifold... step into my thread.

[myblack98gst]

Hi, I'm the guy doing the welding for Donald and I build frames that don't fall apart or crack or leave people standing on the side of the road. The welder I am using is a MIG welder and the welds that are shown in his pic are stitch welds that just fill the gap on the outside of the manifold. The welds I made on the inside which I will send him a picture of to post are much hotter welds that fully penetrated the metal. Now if you know anything about welding metal like this together, when you weld the ends together, as shown in the picture, if you burn though it it could make small holes outside the area you welded on the inside. Now as much as I would like for everything to finish itself that's not going to happen. I just didn't want his little intake to look like a lumpy mess when it was finished. It will all be ground smooth and finished as if it were a body part. Oh and I was just wondering how much heat will affect this part? The exhaust is on the other side of the engine right? Oh well you guys seem really smart so I'll stick with the slave labor and keep doing what I'm doing. Have fun commenting on this topic

 

[Gary 420A RS]

i understanf that you were using temp. tag welds. but it wasnt stated.. but seriously keep the news coming. i would love to see how it comes out.. also when your doing this make a diagram and schematic of the specs. so maybe if it turns out right you can mass produce and profit.

 

[Sk8er07999]

Wow sounds awesome. Make sure to keep us updated with stats and pictures on your project. Good luck!

 

[5150DSM]

Any chance we could get some specs or are you planning on selling this?

Plenum volume?
Runner length and diameter?
Runner taper angle?

Thanks if you can, if not, thanks anyway.
Aloha

BTW- It looks like a nice start, I'd like to see the finished product.

 

[DragGSX]

I just wanna drop my two cents in here...Y does everyone want there surge tank to be square? Am i missing something here...I thing it would be ALOT easier to just take a 4" peice of Exhaust tubing (Or match it with your IC piping/TB size) and cap one end of it, then weld on an adapter plate to match whatever TB you want... This to me makes more cents (might even make dallors ). And would require less welds = less places for potential leaks and would look great also!!!! ive attached a picture of one made of Aluminuim tubbing ina turbo mag.....As soon as i get my TIG welder im goin to start making some of these and tubular headers if anyone wants em (after testing them of course)...gonna sell em real cheap to because i know how it is to be a PAY CHECK TO PAY CHECK RACER!!!!!!!!!!!!!!! Also going to home depot and buying a sheet of 1/8" thick rubber and cutting it into a intake mani gasket adds HP due to less Heat soak from the block. justa lil FYI

Tell me what you think?
BTW: I think that it looks good. Theres always going to be haters when you try to start something,(like years ago when i installed twin14b's on a 3kgt VR-4, everyone thought i was dumb, but now that its been proven everyone's jumpin on the wagon) But as youve posted-you dont care- good job..im that kind of person too, seeing insane prices on tubular headers and intake mani's when it prolly cost them less than 100$ including paying the guy to make it.(most of them are prolly mass made anyway makes me cringe. they rely on the fact that we cant or dont have the tools to make our own stuff.

 

[myblack98gst]

Any chance we could get some specs or are you planning on selling this?

Plenum volume?
Runner length and diameter?
Runner taper angle?

Thanks if you can, if not, thanks anyway.
Aloha

BTW- It looks like a nice start, I'd like to see the finished product.

plenum..

16" long x 4" tall x (4"deep tapering to 2" deep at end of runner)

runner..
6" long x matched to head width x matched to head height & taper to 2.5" at plen..
so approx. 2.5x2.5 at plen. and 2.5x1.5 at head

 

[dj_lethrow]

Very cool. Good to see people trying something different

 

[Stapl3]

where did you get the flange for the head?

 

[5150DSM]

plenum..

16" long x 4" tall x (4"deep tapering to 2" deep at end of runner)

runner..
6" long x matched to head width x matched to head height & taper to 2.5" at plen..
so approx. 2.5x2.5 at plen. and 2.5x1.5 at head

Thanks, I appreciate it. Keep us updated, this is a cool project.
Aloha

 

[gsx951]

I can MIG and TIG. Typically TIG (Tungstan Inert Gas) is prefered for manifold making, but MIG is acceptable. You can only MIG steel. You can TIG aluminum and steel.

Running aluminum in the MIG( G.M.A.W.) process is pretty easy, you just need to change wire and gas. Most production aluminum welding is done with the MIG process.

 

[gixrman]

Running aluminum in the MIG( G.M.A.W.) process is pretty easy, you just need to change wire and gas. Most production aluminum welding is done with the MIG process.

Yup, when I bought my MIG welder i got the adapter kit with it. The only pain is switching everything and having the extra 100% ARGON tank. The nice thing about a TIG welder is the ability to manipulate the weld puddle for solid welds.

 

[MattnGsx]

Any updates on this? Was looking good, but would almost be skeptical to post more because of all the criticism, any ways hope that's not the case.

 

[dsm4lifebeoch]

its looking good man just keep the ball rollin

 

[hellotbone]

Im starting one myself using alot of info I received from this thread. I will take lots of pics and post them as well for guys wanting to do it yourself along with a full list of measurements.

 

[gsx951]

Theres always going to be haters when you try to start something,(like years ago when i installed twin14b's on a 3kgt VR-4, everyone thought i was dumb, but now that its been proven everyone's jumpin on the wagon)

Huh?

 

[92awddsm]

I am subscribing because Im curious also. I will probably be making my own copy of the magnus smim soon also. My plan is to use .090" 6061 for the plenum and runners. Flanges will be made from .350" 6061 and velocity stacks will be machined from 6061 round stock(I am a machinist by trade and have my own lathe). I will just tack it together with a mig and the have it professionally tiged after I am done. In the process, I plan to save about $400 on it just because at the moment, I cant offord the high $ engraving on the top of it. Plus, I have all this just laying oround as scrap so all I really need to pay for is the weding.

 

[WORPeclipse]

I know its a old thread but I take it nothing ever came of this.

 

[Indian]

Uhh... time machine anyone?

 

[gixrman]

I know its a old thread but I take it nothing ever came of this.

If your looking for info on DIY'n your own intake look here
http://www.dsmtuners.com/forums/custom-fabrication/418994-home-made-sheet-metal-intake.html
Theres alot of good info in there.

 

[turboglenn]

In the last 4 years of planing to make it i'm only ONE step akead of you, don't lose motivation. i made the plenum first too, then made the flancge when i picked uip a new mill, but now i don't have anything good for runners and keep just putting it, not so much "back burner" but more like bhind the stove