Doing something stupid, need a flange cut.
 

Who has a CNC mill or can cut me an aluminum NB intake flange?

I'm gonna go for phorum greatness and do some stupid shit with my NB intake manifold.


You know, like this:

https://www.miataturbo.net/attachmen...ine=1448381402

o dis shud bi guud

Oh it will. Car currently looks like this:

https://www.miataturbo.net/attachmen...ine=1448381943

ftjandra bbundy?

https://www.miataturbo.net/miata-par...-flange-78337/

?

Holy sheet! Checking, thanks!

PM humming, he has gotten some stuff water jetted before.

Also call around your local shops, I found someone who could do it real cheap, they were actually a masonry shop, but had a water jet.

I think bbundy had a drawing of it which could then be used at most machine shops/water jet cutters

How quickly do you need one? I posted in the other thread, but I am working on getting these digitized and available. I don't have a time frame yet as they were lower on my todo list, but I have asked my machinist about it.

Put me on the list lars.

I need to get a count of how many people would be interested in purchasing one of these awesome flanges? My machinist said he could do them, but I have to order a few to get it started. I am working on getting numbers right now. I don't have a ton of cash personally to hold stock of them, but if I can get enough interest I can get the first set made. Then the shop would be able to make more as needed.

I know Concealer404 and I would be down.

I'd be interested

What price point would you guys be willing to pay? Would there still be interest if I required payment up front to get them into production?

Considering I have no real idea to base my estimate off since I have no experience purchasing custom water jetted pieces. I'd pay $100-$150 for something like that. I'd probably be saving cost going to a aftermarket intake manifold that fits a honda. I guess as long as I can swap to using a honda manifold under the cost completely of just paying someone to make me a custom intake manifold. If that makes sense.

I'm in for under $50.

I would also be interested in picking up a flange! Don't mind paying in advance.

I'd pay up front toward the purchase of a baller IM

I may be interested in a couple, if you can get us a price point.
I'd prepay with a solid ETA

Yeah I can tell you it probably won't be anywhere near that cheap.

Once I get details on pricing I will make a list of who all is interested and see if I can get enough people in. The shop I use is pretty good, I generally get a 3-4 week turn around when I am buying exhaust flanges in bulk.

I'll probably try and find waterjetting then. Cheaper is better.

I just want to be clear I am going to have the following made.
https://www.miataturbo.net/attachmen...ine=1448412990

Not these ones.
https://www.miataturbo.net/attachmen...ine=1448381402

Ugh, i do like the baller one. Still sub'd

The flange I had waterjet cut cost me $70 AUD (ie $50 USD) to get made out of 12mm Ally. Mine is for a BP05 head and has larger port holes for the Honda manifolds. Files are here: https://lastpixel.box.com/s/vwdgkpy65ok26o0gykhd984iew4my92a

Given the welding, grinding and then surfacing of the flange after it's attached to the intake, I don't think there is much need for a pretty CNC one. You only really need that if you are making a manifold from scratch and the runners can slot into the recess.

Just a couple of notes from when I did my intake. The flange shrunk approx 1.5mm when it was welded to the runners. This meant the end holes didn't quite align and needed some filing. I would move them out or oversize them slightly next time. This may be different per manifold and welder.

All port sizes need to be undersized vertically a little due to the angle of the runners and the head. Once welded these angles need to be ground into the flange. Also, the end two ports need to be undersized horizontally to allow for the angle of these two runners. (NA8_Inlet_Flange_for_Honda.dwg has the end ports reduced by a few mm)

I made my flange out of 12mm so it could be surfaced flat to approx 10mm. You do get some bend in the flange when welding.

If anyone wants them, I can make a CAD profile to suit your application. Just need to know what head and what intake you're going to attach.

edit: The CAD linked above has room for triangular bracing to be attached at the base of the manifold which is why it has the larger flats on the bottom of the flange.

madjak did you bolt the flange to another piece of plate for the welding and got that much warping and shrinking?

Had to heat the flange and manifold in an oven to get the best weld. The thick flange heat soaks otherwise. If you could clamp it to a big chunk if steel and heat that up also it would probably help. I didn't expect so much bananaring.

Do whatever gives the best weld. If you use a 12mm thick flange you have heaps of meat to absorb any warping.

That dirty skunk cast aluminum probably didnt help at all.

I heard back from my machine shop. I would have to get 20 of the flanges ordered at once to get any made. I figure I could sell 5-8 of them to you guys right now. I cannot afford to sit on another 10-12 of them so I am going to pass on getting them made.