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Old 11-24-2015, 08:56 PM   #21
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Originally Posted by aidandj View Post
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.


Not these ones.
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Old 11-24-2015, 08:58 PM   #22
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Ugh, i do like the baller one. Still sub'd
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Old 11-24-2015, 10:31 PM   #23
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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.

Last edited by Madjak; 11-24-2015 at 10:35 PM. Reason: Addition
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Old 11-24-2015, 11:01 PM   #24
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Quote:
Originally Posted by Madjak View Post
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.
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Old 11-29-2015, 12:39 AM   #25
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madjak did you bolt the flange to another piece of plate for the welding and got that much warping and shrinking?
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Old 11-29-2015, 12:48 AM   #26
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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.
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Old 11-29-2015, 01:10 AM   #27
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That dirty skunk cast aluminum probably didnt help at all.
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Old 11-30-2015, 12:18 PM   #28
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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.
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