Intake Manifold Flange
#3
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Scribe round a $12 intake gasket and go nuts with a bandsaw and drill. That's what I did. Finished off the ports with a die grinder and a carbide bit but you could use a file.
I used a piece of thick 6062 (HE30) ally because its easy to weld to just about anything using 4043 rods. Also factor in the warping caused by welding. My first attempt using 8mm sheet went like a bannana so tried again using 16mm plate. It still warped over 1/4" from end to middle to end but I tweaked it back into shape using a 12ton press before skimming it flat on the mill.
I used a piece of thick 6062 (HE30) ally because its easy to weld to just about anything using 4043 rods. Also factor in the warping caused by welding. My first attempt using 8mm sheet went like a bannana so tried again using 16mm plate. It still warped over 1/4" from end to middle to end but I tweaked it back into shape using a 12ton press before skimming it flat on the mill.
#4
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I have some 'fancy' BP4W ones that I used for my intake manifold build made out of 1/2" 6061.
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_1.jpg)
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_2.jpg)
The port holes are angled to match the head and tapered slightly. The flange also has recesses for the tubing to make construction easier. The ports are matched to the gasket.
After a little port matching, the runner tubes end up perfect.
![](http://www.ferdster.com/forum_attachments/atomicEGT_irtb_flange/atomicEGT_bp4w_irtb_flange_3.jpg)
I have two ready to go - $125 shipped each.
If you want to see more pics of my manifold build, they are here.
--Ferdi
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_1.jpg)
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_2.jpg)
The port holes are angled to match the head and tapered slightly. The flange also has recesses for the tubing to make construction easier. The ports are matched to the gasket.
After a little port matching, the runner tubes end up perfect.
![](http://www.ferdster.com/forum_attachments/atomicEGT_irtb_flange/atomicEGT_bp4w_irtb_flange_3.jpg)
I have two ready to go - $125 shipped each.
If you want to see more pics of my manifold build, they are here.
--Ferdi
Last edited by ftjandra; 01-19-2010 at 05:18 PM.
#9
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![Default](https://www.miataturbo.net/images/icons/icon1.gif)
I have some 'fancy' BP4W ones that I used for my intake manifold build made out of 1/2" 6061.
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_1.jpg)
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_2.jpg)
The port holes are angled to match the head and tapered slightly. The flange also has recesses for the tubing to make construction easier. The ports are matched to the gasket.
After a little port matching, the runner tubes end up perfect.
![](http://www.ferdster.com/forum_attachments/atomicEGT_irtb_flange/atomicEGT_bp4w_irtb_flange_3.jpg)
I have two ready to go - $125 shipped each.
If you want to see more pics of my manifold build, they are here.
--Ferdi
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_1.jpg)
![](http://www.ferdster.com/forum_attachments/intake_manifold/flange_2.jpg)
The port holes are angled to match the head and tapered slightly. The flange also has recesses for the tubing to make construction easier. The ports are matched to the gasket.
After a little port matching, the runner tubes end up perfect.
![](http://www.ferdster.com/forum_attachments/atomicEGT_irtb_flange/atomicEGT_bp4w_irtb_flange_3.jpg)
I have two ready to go - $125 shipped each.
If you want to see more pics of my manifold build, they are here.
--Ferdi
beautiful manifold, my hat goes off to you
#20
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ok here is a novel idea, take a intake mani gasket find a local small job shop(machineshop) and say hey can you make me a flange like this gasket out of 6061-t6. leave some extra meat on it. all that really matters is the hole pattern and the ports. what he is asking for the flange above is a good deal, the fact that the port holes are angled is a huge huge plus, and the machine work is top knotch. its a matter of building an intake mani isnt for the faint. so bone up and stop being cheap and lazy!!!