sen2two

this is actually my first attemp at welding/forming aluminum. (6061 T-6) it still needs to be smoothed out and polished. the inside it fully ported and smoothed out for better flow. theres no rough edges inside.



the RB manifold will be ported like this picture below...









its going to use an aftermarket mustang throttle body. i made it so i could convert my 12a to fuel injection. i will not have injectors in this manifold. i will be tapping the RB manifold for fuel.

sen2two

im going to make a similar one for my TII using a Jay-tech lower manifold. i will port the jay-teck one similar to the RB one pictured above also.



for those of you that fabricate here, you have any suggestions on how to improve it?





oh yeah, the throttle body is 75mm. for my TII i was thinking a 90mm...too big?

sen2two

heres a pic of it sitting on a jay-tech manifold for a REW.



i hadnt finished grinding it down yet here. the welds on the sides are all gone now. im going to take it and get glass bead blasted inside and out. after that i'll most likely have it polished. and have the part where it sits on the manifold resurfaced just to be sure...



also, it looks much larger in this pic than it actually is. its really much more proporrtioned to the lower manfiold.

ColinRX7

Your TB flange looks a little bit thin to me. Is the manifold side flange a piece of cast aluminum? I don't see that holding up too well with the 6061. It might be okay for a while but engine/road vibration it will probably crack, if that's the case.

teknics

what does the inside of the box look like? not much we can describe from pics of the outside.



I agree with colin tho the TB flange looks too thin, in the last pic it already looks warped.



more pics...



kevin.

sen2two

yeah it is thin. only 1/8 inch. i planned on adding a 3/8 inch flange but its all i had at the moment. the bottom flange is cast aluminum. i know, but its all i had at the moment also.



this is actually just a test piece, since this was my first attempt at aluminum welding.



heres an inside pic. when i try to get a closer pic my crappy camera gets blurry. and one of the throttle body too. i ported it all down so theres no hard edges. i was thinking of getting it all glass bead blasted then polished...i just might use it.

ColinRX7

It's pretty neat, but I'd be going with 1/2" flanges.



I know it seems excessive, but you will bend that 1/8" thick flange in no time. If I were you, I'd test it and run it, but the moment you have any misfire/bad AFR problems, I'd pull that UIM off, cut off both flanges, get a piece of 1/2" thick x 5" wide flatbar, long enough to do both flanges, and make new ones.



If you don't have the tooling, get it. Die grinder, zipwheel, drill, whatever. Just punch holes in it and die grind the rest of it out. It doesn't have to look like a professional job while your doing it, it has to look like a professional job when it's done. Get the excess material out of your way, leave meat around the inner edges for the port, and finesse the die grinder until it's done. And you can do that with basic pneumatic fab tools. Working with aluminum is a cakewalk compared to working with steel, aluminum drills and grinds way easier. I've had to do some really tedious jobs with steel, which wound up not taking as long as I thought, so don't let the aluminum scare you. You could bang out two new flanges in an afternoon, with aluminum flatbar and basic tools. You just gotta hold your focus, and treat it like it's your job to get it done.



Then you won't have anything to worry about.

sen2two

thanks for the tips.



yeah, the 1 1/2 inch spacer is just to bulky. and i already bent the TB flange...lol.



im starting welding school monday morning...so i should be a lot better soon considering i'll have real training. not garage tech i taught myself.