Hey everybody!

I finally got my custom combination intake/exhaust flange back from the shop! It's milled from 1/2" mild steel and looks awesome. My friends and I are planning on using it for the basis of a single piece intake/exhaust manifold. The intake will be tubular with a throttle body on one end of a log, and the exhaust will be stainless pipes to a turbo flange. I have a pic posted below.

Patrick Devlin




pwd22@drexel.edu

Looks Sweet, when do you go into "mass production"??

Make them 3/4+ thick so we can machine-in the fuel injector bores (.635-.640 dia) and that would save on intake manifold conversion work.
DD

Well, Doc. I mentioned to the guy at the tool & die that I should've asked on the Internet to see if anybody else wanted one made. Maybe next time, after I see how this works out. That manifold spacer is a cool idea. The only thing needed would be longer manifold mounting studs.

One of the main motivating factors of going single piece is so that I never have to drop triangular washers on the driveway again. This thing is going to be designed with enough clearance to get a wrench in there easily, too.

Hopefully, my friends and I will get started on this soon. I already have all the pipes, turbo flange, and 4.6L Mustang throttle body.

Catch ya later!

Pat


pwd22@drexel.edu

That piece is what I've imagined for my delayed EFI project! No more gasket leaks. Are you going to weld the stainless steel exhaust tubes to the flange?

I'd want to get a 2nd hand Bridgeport type milling machine and build custom parts similar to your flange, create specialized tooling etc. I've heard that older CNC units cost less than manual mills as the electronics often need repairs, cheap aftermarket control modules are available for retro fit. We need a more hobby machinists in the old car hobby. I have no experience with CNC, it's just something I want to learn.

Hey Tim,

Yep, I'm going to weld stainless pipe to the flange for the exhaust. In the picture below you can see the flange for the T04 turbo. It will be six stainless pipes to the turbo flange.

Having machinists in the hobby is especially important when you're running a motor that the aftermarket likes to ignore. I already have hundreds of dollars into this manifold...and its in pieces! (this is what a college student who doesn't spend his money on liquor or drugs blows his money on)

Be sure to let everyone know when you master that CNC stuff; you'll make lots of new friends!

Pat


pwd22@drexel.edu

Is that going to be a problem, welding SS tubes to a mild steel flange?


fglmopar@aol.com

Hey Bud,

I'm not very experienced when it comes to welding, but I'm pretty sure you can weld 304 stainless to mild steel without a problem. Friends of mine have made turbo headers this way. Maybe the weld will just not have the greatest corrosion resistance...I don't know. Is there anything I should know before attempting to weld 304 stainless pipes to a mild steel flange?

Pat


pwd22@drexel.edu

Neither am I. I guess I have welded mild steel to mild steel with stainless rod, successfully. I don't know if there would be a problem or not. Any expert welders out there with an opinion?

fglmopar@aol.com

I believe with turbo and custom manifolds you could run the exhaust tubes over the intake, if that would help with the plumbing. With the EFI setup you have more design flexibility for the manifolds than with a carb.

Yeah, that would be cool too. I have plenty of room for long runners, seeing as it's going to be in a '68 Dodge Dart with manual everything.


pwd22@drexel.edu

When you get it all together you can post on the new Buy/Sell forum on the new board and see if you get enough takers. You can also list yourself in the parts database.

Chuck


sl6@omnipages.com

hey guys i was talking to rob, actually he e-mailed me and this seems like it would be a pretty simple part to make. he said approximately 1.5" thick with threads for the injectors. he is going to draw it up, and ill go ahead and make it. i know CNC and all that stuff.

also tim i read your post. getting an old bridgeport is a great idea, they are relatively cheap and reliable. also CNC is tough to master, but i reccomend a straight forward mod to your bridgeport:

protrack, ez-track, and anilam are basically really simple CNC setups that connect right to a bridgeport. easy to learn, very reliable, and will do just about anything on the parts you would like to make for your engine. these mods are also relatively cheap and reliable.

anyways me and rob will get to work on the fuel injector plate, any input would be great.

_________________
e-mail me if you need a custom part for your car or engine made! machined or fabricated!
inthemorrow@hotmail.com

Isn't it preferd to angle the injectors towards the valves instead of straight down?

yeah we were talking about it
simply machine a 45 degree angle, so then the injectors will be pointed towards the valves.
[corny joke]so then the engine AND the injectors would be slanted!!![/corny joke]

_________________
e-mail me if you need a custom part for your car or engine made! machined or fabricated!
inthemorrow@hotmail.com

Just an update to my intake/exhaust idea:

I haven't done anything with the parts yet! More than a year later. It's hard to modify a daily driver when it's your only car, don't have a full-time job, and are still in school.

Eventually, I'll probably build it. But for now, for reliability, money, and time reasons, I'm sticking with my Weber carburetor.

_________________
'68 Dodge Dart 4dr Sedan