Intake Manifold Flange
 

Where can I buy a couple aluminum intake manifold flanges? Can't seem to find them anywhere.

I have a drawing for one if you can find a place to machine it out. I used 1/2" 5052 aluminum and welded a 99 flange onto a 95 manifold minus all the egr casting features. Somebody on the PSMG list, Jon? had it made for me and I traded a 99 manifold for it.

Bob

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 have some 'fancy' BP4W ones that I used for my intake manifold build made out of 1/2" 6061.

http://www.ferdster.com/forum_attach...d/flange_1.jpg

http://www.ferdster.com/forum_attach...d/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_attach...b_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

Nice!

Bob

That's nice, I'll let you know.

So FTjandra. If you had orders for 10 of the manifold you built modded for Miata use, how much chashola could you build them for !!!

The main problem is that I can't weld aluminum.

--Ferdi

beautiful manifold, my hat goes off to you

very very nice work, puts me to shame. but then again i did mine manualy

Anyone else know of a (cheap) source for these flanges or am I asking the impossible?

Get in touch with aaron at weirtech and see if you can send him a drawing to have him make one. Also check with that guy BMCrace perhaps?

You could try getting in touch with the guy who owns Weirtech. He claims to offer the best flanges at the lowest prices. I don't spot a BP intake mani flange on his website but apparently if you provide him a gasket he can machine them at a reasonable price...

pwnd :(

:laugh:

Anyway, as far as I can tell he is correct in that he offers the cheapest flanges. It just takes a decade to get them after you order lol.

Don't say that

Looks like I'll just cut up a couple of manifolds and get what I need immediately.

All I see at Weirtech for any brand vehicle are exhaust flanges, not intake. Am I missing them?

No you're not. What you're missing is a few posts up where Jeff and I suggested he talk to Aaron about possibly making them ;)

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!!!

Thanks. I can get a 'plain' flange made much cheaper - maybe around $65.

As for Weirtech, I believe he uses a laser cutter, which can't cut aluminum.

--Ferdi

Lulz, JayL cheap and lazy, you're funny.

This suggestion, although possible, will easily run you over the other guy's offer of $125 for an already made flange. Even if the material was free, you're talking 2-3 hours of labor unless they have some sort of CMM and a water jet. Small job shop won't have that equipment, so you're suggesting a $160-240 solution.

Thanks, but for what I'm doing cheap and now is a requirement. The shops I went to today aren't exactly willing to do it for any less (actually more) and the estimated completion date would be almost a month out. I already have a manifold made and this is to just make a separate piece so I can play around with runner lengths to see what works best for me. I can see doing the final product nicely after I determine exactly what I want, but this piece will just be getting hacked up as it evolves.

As for being cheap, I didn't get where I am in life by throwing my money away. As far as being lazy, how's your car coming along, still sitting in the same spot it was two years ago? :fawk:

wow pretty harsh

as for cheap, im a firm beliver of you get what you pay for
as far as lazy. figure out a way to make it yourself if you dont want to pay for it.

as far as my car. id say its far more complex than 90% of the cars on here and the fact that 60% of the work was done by my self on 1.5 - 2 days a weeks work. yeah i work 2 jobs 60 plus hrs a week the other time, to be able to afford building the car without being in any debt at all. then limited by no garage and harsh new england weather. id say im moving alot pretty good. :vash: