ok, i dont know where else to post this...



so im about 90% done with making my intake manifold. it uses a holly flange so i can use it on any racing beat and jay-tech syle manifold. basically so you can go from carb to fuel injection easier. i made it out of a sheet of 1/8 inch thick 6061 T-6 aluminum. basic design. but very functional. i was thinking about using the stock FD throttle body cause its already been wired into s4/s5's a bunch of time, and i currently am running it on my FC. but i decided to go with a much better design and us a 75mm mustang throttle body. i have been told the TPS are very identical to the FD one and is easily wired in. so i can even be used with the stock ECU. ok, thats a little backround...



now a few places have a 90* edge where the air will be flowing. like this "L".....now, i cant get in there to weld down the edge and grind it out smooth. but i can easily get my hand in there to use a puddy or something similar to smooth out the edge. (think caulk on an edge when sealing a speaker box or similar).



so, what puddy to use? i need something that i can lay on smooth like caulk but will harden like JB weld and stay there even with 30psi pushing past it.



any ideas? experience with this?

devcon

thats what first came to mind.



how good does it bond to metal? i know it get hard like metal. but i need it to stick and stay...

Since 6061 t-6 is not a weldable alloy, I am assuming that you will be glassing the whole thing together?



In that case, any location that should have a radius, can be produced by building up a thick epoxy filet on the outside of the joint. Add glass cloth over that to keep things together. Cut the plenum in two in the vertical plane.



Die grind the radius you want, on all of the runners and glass the whole thing back together when finished. Build a thin stainless shield between all of the intake stuff and the exhaust. No line of sight connections without a shield.



Use Devcon Plastic Aluminum putty.



Lynn E. Hanover

t6 aluminum is weldable. i orded it a sheet of 6061 t-6 aluminum and thats what i made it out of. and its welded together right now. its the most common used alloy for intake manifolds.



most starter flanges are made from 6061. really, just about every one i have ever seen was that same alloy. but this is not what we are discussing...



i need to know if the Devcon aluminum puddy will stay inplace under boost when i squish into the edges...?

NASCAR engine builders are known for using Devcon epoxies for quickly modifying cylinder head ports or intake manifold runners and then taking them to the track to see how the new shape works. Of coarse they don't race with them like that but I can tell you they will hold up to some high heat and stress for a good amount of time. Don't bother with the over the counter Devcon epoxies though, some guy at work gave me some he got at a hardware store and it wasn't worth a crap.



I have used Quick Steel that you can get at wal-mart on my exhaust before and as long as the surface was clean and I made the patch wide to give it extra surface area to bond to it held up to that so I would imagine some Devcon steel filled epoxy would do the job ok.

Belzona 1121



i have also used the alum and conventional devcons

usually to block the EGR, ACV and water crossover passages

all will do,

the belzona is the better, longest lasting, superior grab product though