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View Full Version : Mike's Badass Quad Carb Manifold!! Build PICS!!!



Ichiban
11-08-2009, 04:21 PM
Because it has a carb. And it's about to get worse, 'cause he's getting 4 of them:bong:


http://i82.photobucket.com/albums/j263/guyhatesmycar/004.jpg
Started milling.

http://i82.photobucket.com/albums/j263/guyhatesmycar/005.jpg


http://i82.photobucket.com/albums/j263/guyhatesmycar/005.jpg


http://i82.photobucket.com/albums/j263/guyhatesmycar/008.jpg


http://i82.photobucket.com/albums/j263/guyhatesmycar/010.jpg

Someone on 3geez told me once that the A20/B20A leans forward at a 15 degree angle. Lets hope so, or else John's carbs are gonna hafta suck at an angle.


http://i82.photobucket.com/albums/j263/guyhatesmycar/011.jpg

Meet the worst mill vise in the world, world, worst mill vise ever....


http://i82.photobucket.com/albums/j263/guyhatesmycar/013.jpg

Gotta lay out some holes! Hope that center spacing is in fact 85mm, 90mm, 85mm!

http://i82.photobucket.com/albums/j263/guyhatesmycar/015.jpg

Big holes now!

Ichiban
11-08-2009, 04:27 PM
http://i82.photobucket.com/albums/j263/guyhatesmycar/016.jpg

Someone on here flamed me once for suggesting drilling a 1/2" hole. Showed them...

http://i82.photobucket.com/albums/j263/guyhatesmycar/017.jpg

The boring head makes an accurate, snug fit over the tubes...

http://i82.photobucket.com/albums/j263/guyhatesmycar/019.jpg

Digi makes it easy...

http://i82.photobucket.com/albums/j263/guyhatesmycar/020.jpg
http://i82.photobucket.com/albums/j263/guyhatesmycar/021-1.jpg

...life is sooo boring....

http://i82.photobucket.com/albums/j263/guyhatesmycar/022-1.jpg

They fit!

http://i82.photobucket.com/albums/j263/guyhatesmycar/023-1.jpg

Cut to the same length. We're not building a GM here, people!

http://i82.photobucket.com/albums/j263/guyhatesmycar/024.jpg
http://i82.photobucket.com/albums/j263/guyhatesmycar/025.jpg
http://i82.photobucket.com/albums/j263/guyhatesmycar/028-1.jpg

Mocked up, and tacked into place.

Ichiban
11-08-2009, 04:32 PM
http://i82.photobucket.com/albums/j263/guyhatesmycar/030.jpg

Squishy squishy!

http://i82.photobucket.com/albums/j263/guyhatesmycar/031.jpg

MORE squishy squishy!!

http://i82.photobucket.com/albums/j263/guyhatesmycar/035.jpg
http://i82.photobucket.com/albums/j263/guyhatesmycar/034.jpg

Not too bad of a fit...

http://i82.photobucket.com/albums/j263/guyhatesmycar/036.jpg

First runner welded up...

http://i82.photobucket.com/albums/j263/guyhatesmycar/037.jpg

And precisely HERE is where I ran out of fucking MIG gas.


More when the bottle is full!!!.....11!!

A18A
11-08-2009, 04:40 PM
awesome work there!! top stuff

Hazwan
11-08-2009, 04:45 PM
Fuck that is sex!!!!!

2ndGenGuy
11-08-2009, 06:55 PM
Holy shit dude! That's fucking rad! Looks awesome!! Thanks so much for the work! Hope you're having fun making that shit. BTW, if anybody needs any shit done, this guy is the man!

Ichiban
11-09-2009, 05:04 PM
Hey John, feel free to rename this thread so it makes sense to everyone!!

Civic Accord Honda
11-09-2009, 05:35 PM
WinRAR

MessyHonda
11-09-2009, 07:44 PM
now that is how you build a real manifold

Pico
11-09-2009, 07:54 PM
Amazing work

AccordB20A
11-09-2009, 08:32 PM
man that looks good mike john will be one happy chappy

2oodoor
11-10-2009, 06:39 AM
Absolutely amazing!

lostforawhile
11-10-2009, 07:59 AM
what ? no JB weld? :cheers: boy this brings back memories, maby i will be able to finish mine one of these days, i had to do the same thing with the plate thats tig welded on to the piece of factory manifold on mine, lets see more details of how you matched the ports where the round edge and oval piece come together. I still need to do a little bit of port matching. also how are you going to support the manifold from underneath? how are you going to add a balance tube? you really need one with that many carbs or they will do all kinds of weird things.

2ndGenGuy
11-10-2009, 09:19 AM
I already tapped 4 NPT bungs in the runners on the stock part of the manifold. Those will feed into a collector box of sorts, but only for MAP/vacuum purposes. I don't know if there's really any need for balance tubes for the purpose of the carburetors. Seems kinda like it would kill the whole point of the individual runners... They didn't have any sort of setup like that as they were practically bolted to the cylinder head on the motorcycle they came off of. The original "manifolds" were just little rubber grommets of sorts.

2oodoor
11-10-2009, 10:28 AM
^^^ the bungs on each tube and routed to a common "box" should do the trick.
factors to consider:
*vacuum drop at off idle throttle to wot and carb setup matching to engine load
*cam profile and head flow charactoristics in regards to getting the vacuum required to pull from idle circuits of carbs x4 zomg
*vacuum draws sa pvc-brake booster etc you do not have on a scooter


Also To give an example of how variances of can affect our carb set ups: I put a progressive style weber 32/36 on my dx that has the cygnusx1 "spread bore" intake (oem with plenum divider cut out completley to accomdate a weber 38 full time 2 bbl carb) and it runs just like doggy doo. The same carb ran beautifully on the stock oem intake. I understand why, but it is amazing to see how much different the carb behaves. There is plenty of go power once the engine opens up but low end is nothing nadda.

Ichiban
11-10-2009, 06:16 PM
i had to do the same thing with the plate thats tig welded on to the piece of factory manifold on mine,


Believe it or not, that is actually aluminum MIG.




lets see more details of how you matched the ports where the round edge and oval piece come together. I still need to do a little bit of port matching.

There's not really much to show right now, I crimped the tubes in the vise to the same height as the ports, however they are slightly lacking in width. As you can see, the carb spacing is slightly narrower than the port spacing, causing the two outer ports to be offset slightly to the inside. The two center ports are as well, but not as much. In fact, the outer ports came flush to the inside edge of the tubes, where the inner ports are more centered over their tubes. I plan on adding material to the inside of each port where it is shy, the outside of the tube, and splitting the difference in a gradual blend.

Surprisingly, reusing the factory manifold flange actually helped somewhat as the short leftover lengths of runners already begin that inward curve.



also how are you going to support the manifold from underneath? how are you going to add a balance tube? you really need one with that many carbs or they will do all kinds of weird things.


I didn't really have any plans yet for an underbrace. As it is, the intake only weighs like.0003 pounds, and most of that is the flange. Balance tube? I suppose I'll leave that up to the customer!

2ndGenGuy
11-10-2009, 06:47 PM
^^^ the bungs on each tube and routed to a common "box" should do the trick.
factors to consider:
*vacuum drop at off idle throttle to wot and carb setup matching to engine load

That shouldn't be a problem since the carbs I have a CV carbs. I believe that is the other way to prevent the vacuum drop off since the carbs don't have accelerator pumps.


*cam profile and head flow charactoristics in regards to getting the vacuum required to pull from idle circuits of carbs x4 zomg

I haven't read everything on B20A cams yet, but I've been reading a lot on PreludePower and the 3g B20A, since they've got mostly the same internals and share cams. But yeah, that will definitely be something to consider. Maybe a 1500RPM idle? :devil:



*vacuum draws sa pvc-brake booster etc you do not have on a scooter

I was reading about Cygnus' setup with his ITBs and from what I can remember, he ran his booster to just one runner, and there was more than enough vacuum to run his booster. But I could be thinking of someone else. Lots of DCOE manifolds I've seen are set up this way too, with one bung on only one runner. I guess I'll find out myself soon. :D


Also To give an example of how variances of can affect our carb set ups: I put a progressive style weber 32/36 on my dx that has the cygnusx1 "spread bore" intake (oem with plenum divider cut out completley to accomdate a weber 38 full time 2 bbl carb) and it runs just like doggy doo. The same carb ran beautifully on the stock oem intake. I understand why, but it is amazing to see how much different the carb behaves. There is plenty of go power once the engine opens up but low end is nothing nadda.

I see what you're saying. I wondered how much that would change the way the car runs and drives. On my 1gee, I'm running a 32/36 and I cut out the divider as much as I could. It's not completely gone, but mostly. I've still got a ton of off idle throttle response with that motor. Could be the cam though, since the power pretty much dies off at 5500RPM really hard. I wonder if a stock plenum with some dividers built up and matched all the way up to the carb would help my top end at all...

Ichiban
11-15-2009, 10:31 AM
Seems that the shop is being gay about not getting more argon for Al MIG until there's a panic rush job need for it. In which case they won't have it:wtf:

So hopefully someone comes in soon for aluminum, because the shop refuses to refill the bottle just for John's manifold.

2ndGenGuy
11-15-2009, 12:42 PM
Don't they realize the importance and impact on humanity this manifold will have?

Rendon LX-i
11-15-2009, 12:49 PM
thats some sexy work

Ichiban
11-15-2009, 01:02 PM
Don't they realize the importance and impact on humanity this manifold will have?

I think they're pissed off at me for my miserable attitude at work all week:burn:

Lil Mike
11-16-2009, 03:34 PM
Don't they realize the importance and impact on humanity this manifold will have?

i agree. this thing is awesome! makes me want to make my manifold agian.

cygnus x-1
11-16-2009, 08:08 PM
Bitchin man, a quad carb setup! Looking good so far. Makes me wish I had aluminum welding capability. Having just gone through a failed ITB build (failed for the time being anyway) I can say welding up the runners is the way to go. I tried using silicone couplers, which did work but they have very little mechanical strength, and need bracing to make sure they don't come apart.

A balance tube shouldn't be absolutely necessary as long as the carbs have some means for adjusting the throttle blades relative to each other. What kind of carbs are going on here anyway?

For the brake booster and other vacuum stuff it would be better to tap from all of the runners equally to spread the draw out. I tried running the booster from a single runner and it did work but I wouldn't do it permanently.

What engine is this going on? Any other mods on it?


C|

Ichiban
11-17-2009, 10:39 PM
Bitchin man, a quad carb setup! Looking good so far. Makes me wish I had aluminum welding capability. Having just gone through a failed ITB build (failed for the time being anyway) I can say welding up the runners is the way to go. I tried using silicone couplers, which did work but they have very little mechanical strength, and need bracing to make sure they don't come apart.

A balance tube shouldn't be absolutely necessary as long as the carbs have some means for adjusting the throttle blades relative to each other. What kind of carbs are going on here anyway?

For the brake booster and other vacuum stuff it would be better to tap from all of the runners equally to spread the draw out. I tried running the booster from a single runner and it did work but I wouldn't do it permanently.

What engine is this going on? Any other mods on it?


C|


Apparently the carbs will be Mikuni BST 38SS carbs. The engine is a (first gen) JDM B20A gold top. Ask 2ndgenguy about mods, I'm sure there will be several.

I'm still trying to dream up a better vacuum manifold setup, but haven't really figured anything out for sure. As I remember, the ET2 twin carb setup runs the brake booster off of one or two ports only anyways. That system also has enough additional vacuum lines to build a large slingshot with:nuts:

How'd the ITB's fail? Maybe I could somehow help, provided the shop hasn't permanently vetoed Al Mig gas for the foreseeable future.

2ndGenGuy
11-18-2009, 12:34 AM
They're 38mm carbs from a GSXR750. I wasn't sure if they were going to be big enough to run a 160hp motor. But I calculated the airflow compared to a single stock throttle body and there does seem to be about 50% more throttle area with these. But that's all I really have to go on, some trial and error.

I'm not 100% sure on what mods yet. I don't think I'm going to do anything super wild yet. Compression bump, some cams, get some bottom end lightening done... Not sure yet if I want to do headwork or not. Definitely will have to have a custom header built for it. Hope to get maybe 180bhp out of it. Hopefully the carbs can keep up. Hopefully I can figure out how to jet them, and change the needles and all that. I'm hoping that the fact that they're CV carbs will let them be forgiving. The car ran and idled with the stock jetting on the carbs, so it can't take too much. Here's a video I did before I had Mike make me his badass manifold, and before I found out the engine was fucked:

http://www.youtube.com/watch?v=pPs92KrCaj8

I hardly think your ITB project was a failure. It's probably pretty frustrating for you at this point, but there's still some interesting potential there. Did you ever get videos of how your car was running, or maybe some pics of that manifold all assembled and installed on the car with the throttle bodies?

lostforawhile
11-18-2009, 07:15 AM
They're 38mm carbs from a GSXR750. I wasn't sure if they were going to be big enough to run a 160hp motor. But I calculated the airflow compared to a single stock throttle body and there does seem to be about 50% more throttle area with these. But that's all I really have to go on, some trial and error.

I'm not 100% sure on what mods yet. I don't think I'm going to do anything super wild yet. Compression bump, some cams, get some bottom end lightening done... Not sure yet if I want to do headwork or not. Definitely will have to have a custom header built for it. Hope to get maybe 180bhp out of it. Hopefully the carbs can keep up. Hopefully I can figure out how to jet them, and change the needles and all that. I'm hoping that the fact that they're CV carbs will let them be forgiving. The car ran and idled with the stock jetting on the carbs, so it can't take too much. Here's a video I did before I had Mike make me his badass manifold, and before I found out the engine was fucked:

http://www.youtube.com/watch?v=pPs92KrCaj8

I hardly think your ITB project was a failure. It's probably pretty frustrating for you at this point, but there's still some interesting potential there. Did you ever get videos of how your car was running, or maybe some pics of that manifold all assembled and installed on the car with the throttle bodies?
38 will be fine, the SU's flow more then a conventional carb, and they run 6 cyl all out Datsun race motors off of these , well more then 160 horsepower. that's with two,with four conventional carbs ,you have nothing to worry about. I've seen V8 hot rods run four sidedraft carbs similar to what you are running.

cubert
11-18-2009, 09:41 AM
2ndgenguy:

Did you say jetting and needles?

:D



http://i117.photobucket.com/albums/o61/d16z6broncoII/11-18-09024.jpg



Let me know if I can help out at all with the jetting/parts/etc..

cygnus x-1
11-18-2009, 10:18 AM
I'm still trying to dream up a better vacuum manifold setup, but haven't really figured anything out for sure. As I remember, the ET2 twin carb setup runs the brake booster off of one or two ports only anyways. That system also has enough additional vacuum lines to build a large slingshot with:nuts:


Nothing fancy required. All you need is a small port on each runner, each run to a vacuum can of some sort. Here's a fancy one:

http://www.go-autoworks-store.com/govalogma.html

People have even used short pieces of PVC pipe with the ends capped. All it has to do is withstand atmospheric pressure without leaking. Anything that requires vacuum is then connected to the can.




How'd the ITB's fail? Maybe I could somehow help, provided the shop hasn't permanently vetoed Al Mig gas for the foreseeable future.


They failed mostly because it was nearly impossible to keep all the throttle plates synchronized. This was exacerbated by the TBs being too large for the engine in the first place. An unrestricted 45mm bore for each cylinder means that the tiniest change in throttle opening at idle makes a huge change in airflow. It was so sensitive that even the nearly imperceptible flex in the throttle shafts (twisting) would cause a large difference in airflow between the #1 and #4 cylinders. With larger throttle openings and higher RPMs they were ok, but idle and cruising were sketchy at best.

Theoretically I could have redesigned the linkages to make them work but it was getting to the point where it wasn't worth the trouble. There were other things about the manifold and fuel system that I wasn't thrilled with either so I decided to give up on the GSXR TBs and just put together an Extrudabody setup. The cost is quite a bit higher but the design is just so much better. And this time I'll use 40mm TBs instead of 45mm.

C|

2ndGenGuy
11-18-2009, 10:46 AM
2ndgenguy:

Did you say jetting and needles?

:D


Let me know if I can help out at all with the jetting/parts/etc..

I may be bugging you soon! :D

cygnus x-1
11-18-2009, 10:56 AM
They're 38mm carbs from a GSXR750. I wasn't sure if they were going to be big enough to run a 160hp motor. But I calculated the airflow compared to a single stock throttle body and there does seem to be about 50% more throttle area with these. But that's all I really have to go on, some trial and error.

Those will be just fine. The stock 2g Prelude carbs were I think even smaller than that and there were only 2 of them. Smaller bores make for better throttle response and fuel mixing anyway.



I'm not 100% sure on what mods yet. I don't think I'm going to do anything super wild yet. Compression bump, some cams, get some bottom end lightening done... Not sure yet if I want to do headwork or not.

At the very least get a good 3 angle valve job done. Most gains in head flow are from reworking the valves and seats anyway. Not from "porting and polishing".



I hardly think your ITB project was a failure. It's probably pretty frustrating for you at this point, but there's still some interesting potential there. Did you ever get videos of how your car was running, or maybe some pics of that manifold all assembled and installed on the car with the throttle bodies?


I don't think I ever took any pictures when I had them running. I never really got much further than roughing them in anyway. In a sense they were more of a "proof of concept" than a reliable working system. The concept being an A20 engine running on way over-sized GSXR (1300) ITBs. I think the resulting conclusion was "plausible" but not practical. And honestly I'm not frustrated at all. I had no serious expectations about the outcome and much was learned in the process. What I do know though is that I will absolutely make another attempt at an ITB setup. The individual runner idea is a good one and worthy of pursuit. But this time I'll have a much better idea of what will work and what to watch out for.

Incidentally if anyone wants to check out the thread it's here:
http://preludepower.com/forums/showthread.php?t=287583&highlight=itb

I'll apologize now for not taking enough pictures. :lol: I'm kinda lazy and my camera is old and tired. :rolleyes:



C|

2ndGenGuy
11-19-2009, 10:12 AM
At the very least get a good 3 angle valve job done. Most gains in head flow are from reworking the valves and seats anyway. Not from "porting and polishing".

What do you think about oversized valves? Would I want to do some mild porting to the head to account for the additional flow through the valves? Do you know if a 5 angle grind is typically more expensive?



I don't think I ever took any pictures when I had them running. I never really got much further than roughing them in anyway. In a sense they were more of a "proof of concept" than a reliable working system. The concept being an A20 engine running on way over-sized GSXR (1300) ITBs. I think the resulting conclusion was "plausible" but not practical. And honestly I'm not frustrated at all. I had no serious expectations about the outcome and much was learned in the process. What I do know though is that I will absolutely make another attempt at an ITB setup. The individual runner idea is a good one and worthy of pursuit. But this time I'll have a much better idea of what will work and what to watch out for.

Incidentally if anyone wants to check out the thread it's here:
http://preludepower.com/forums/showthread.php?t=287583&highlight=itb

I'll apologize now for not taking enough pictures. :lol: I'm kinda lazy and my camera is old and tired. :rolleyes:

C|

I've been following that thread anxiously since you started it. Every new post you made was really cool! I learned a lot, as I usually do from your posts!

cygnus x-1
11-21-2009, 11:20 AM
What do you think about oversized valves? Would I want to do some mild porting to the head to account for the additional flow through the valves? Do you know if a 5 angle grind is typically more expensive?


I think bigger valves are almost always going to flow better. But I known very little about the B20A. That is a 16v engine right? The 16v engines are not as restricted and the 12v engines so bigger valves might not make as much difference.
5 angle valve grinds are more expensive than 3 but the flow difference will be minimal. 5 angle would only be for an all out no expense spared race build.
Most Honda heads are pretty good from the factory. They generally don't need much more than just the casting marks cleaned up and any sharp edges removed, especially in the combustion chamber. Any more than that and you really want to make sure the person doing the porting knows what they're doing, and has A LOT of experience with Honda heads.




I've been following that thread anxiously since you started it. Every new post you made was really cool! I learned a lot, as I usually do from your posts!


That thread may sit dormant for awhile but it's certainly not dead. It will be back!


C|

Ichiban
11-26-2009, 07:09 PM
Have gas again. Depending on whether or not I work this weekend, I'll finish up that mani. If I work, Sunday it gets done. If not, my Toyota is undergoing major surgery (front clip re+re)

2ndGenGuy
11-26-2009, 08:41 PM
Dude, no hurry man. If you've got shit to do, do your shit first! I appreciate your hard work!! :D

Hazwan
11-27-2009, 04:26 AM
Dude, hurry up man. If you've got shit to do, do MY shit first! I appreciate your hard work!! :D

There, fixed for you

Civic Accord Honda
11-28-2009, 11:28 PM
There, fixed for you

http://quakeragitator.files.wordpress.com/2009/05/what_he_said.jpg

Ichiban
11-29-2009, 03:18 PM
Gonna work on it during afternoons after work this week.

Ichiban
12-02-2009, 08:38 PM
Weatherford really caused afternoons to shit the bed. This weekend it is, I promise!

Also, I've been trying to get Rob to Mastercam up a simple program to CNC port the thing after I've finished welding it!:wtf::cheers:

cygnus x-1
12-03-2009, 03:48 PM
Weatherford really caused afternoons to shit the bed. This weekend it is, I promise!

Also, I've been trying to get Rob to Mastercam up a simple program to CNC port the thing after I've finished welding it!:wtf::cheers:

CNC porting would be cool! Not sure how "simple" the program would be. I did CNC my entire ITB manifold though and it wasn't that bad. Really, coming up with the model is harder than writing the NC code. Once you have the model it's just defining the toolpaths and tools, work out the fixturing, load the tools, and press the green button. :D

C|

Ichiban
12-12-2009, 08:20 PM
This is all you get right now.

http://i82.photobucket.com/albums/j263/guyhatesmycar/100_1018.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/100_1019.jpg

2ndGenGuy
12-12-2009, 11:10 PM
Dude sweet! I am pretty fucking giddy with excitement! Maybe to speed things along, I should find out how much that import shop in Seattle is selling those "low mileage" B20A's for. Have one to drive, and can rebuild the NZ motor...

Dr_Snooz
12-13-2009, 08:09 AM
Dude sweet! I am pretty fucking giddy with excitement! Maybe to speed things along, I should find out how much that import shop in Seattle is selling those "low mileage" B20A's for. Have one to drive, and can rebuild the NZ motor...

I can't even find an A20 and you have B20s???? You get the big raspberry my friend.

http://www.animationmagazine.net/pressbox/Henry%20blowing%20raspberry.jpg

Ichiban
12-13-2009, 09:26 AM
I should find out how much that import shop in Seattle is selling those "low mileage" B20A's for.

What?

2ndGenGuy
12-13-2009, 11:00 AM
Yeah, someone on here posted a link to an engine importer on here. Nobody but me replied to the thread for some reason. But they had 86-89 Accord motors listed... A20s and B20s.

Ichiban
12-13-2009, 05:47 PM
http://i82.photobucket.com/albums/j263/guyhatesmycar/002.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/0042.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/0052.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/0072.jpg

A20A1
12-13-2009, 10:15 PM
Thats very nice



I'm not sure if it's really an issue, and your manifold is pretty much a straight shot to the valves, but have you considered fuel possibly dragging on the smooth surfaces?

The only two suggestions I have for nicely roughing up the interior would be sandblasting or etching with acid, just to get a smudgin of texture to the inside.

Ichiban
12-15-2009, 09:09 PM
I was gonna rough up the entire inside with a 60 grit flap wheel. I thought that might be coarse enough?

Ichiban
12-31-2009, 05:40 PM
Gonna do some more this weekend! Ship soon!!:jaw:

Ichiban
12-31-2009, 05:42 PM
Maybe to speed things along, I should find out how much that import shop in Seattle is selling those "low mileage" B20A's for. Have one to drive, and can rebuild the NZ motor...

Go fucking find out already.

2ndGenGuy
01-03-2010, 06:26 PM
Oh yeah. Sorry, I was in Mexico all last week and doing "Christmas Shit" before that.

Ichiban
01-12-2010, 05:59 PM
Hey, when do you want this thing? I really want to finish it up nice before I ship it, but I tore the cartilage apart that holds my chest together. I'd love to get this thing cleared up and shipped before, say, weekend after next?

All it needs is a couple low spots filled in the weld, spatter cleaned off and porting finished, outside welds blended, polished all over, and seal face machined;)

2ndGenGuy
01-12-2010, 06:56 PM
Dude, are you okay? That sounds terrible. I was wondering where you've been. No worries. I'm not picking up that other B20A until next month anyways. So, no sweat man. Take your time, as much time as you need to really make it pretty! :D :D Hope you are doing allright.

Dr_Snooz
01-12-2010, 08:12 PM
Um...yeah. What he said ^^^. What happened? R U O K?

Ichiban
01-15-2010, 09:59 PM
I'm on two weeks light duties pending doctors re-evaulation at the end of two weeks.

Hauling on the chuck wrench of a semi-fucked old lathe is what actually caused this injury....

Ichiban
01-30-2010, 08:07 PM
Well I'm back:wave:

http://i82.photobucket.com/albums/j263/guyhatesmycar/002-1.jpg

I didn't go for a full cleanup on the welds, because I don't want to sacrifice any material on the thin (.040") tubing. The bottom side is a bit more austere, but the only thing that will be seeing that is John's oil filter.

http://i82.photobucket.com/albums/j263/guyhatesmycar/003.jpg

There's some spatter inside the tubes that's proving impossible to remove. I'm gonna try wrapping some 120 grit around a shaft chucked in my drill tomorrow to get rid of it.

http://i82.photobucket.com/albums/j263/guyhatesmycar/009-1.jpg

I started thinking about a particular thread here on 3gizz and before I knew it, I'd polished the flange to a shining luster!

http://i82.photobucket.com/albums/j263/guyhatesmycar/011-2.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/001.jpg

Brought to you by Acid Rain hot sauce and rye whiskey! ...Honorable mentions to the propane tank in my livingroom!

Hazwan
01-31-2010, 03:24 AM
Sexy!

cubert
01-31-2010, 07:39 AM
Damn...ill have to try booze with hot sauce next time I want to get something done :lol:


Looks great!!

Dr_Snooz
01-31-2010, 09:53 AM
http://i82.photobucket.com/albums/j263/guyhatesmycar/001.jpg

Brought to you by Acid Rain hot sauce and rye whiskey! ...Honorable mentions to the propane tank in my livingroom!

Awesome! The manifold is nice too.

2ndGenGuy
01-31-2010, 10:38 AM
Holy shit! That looks fucking awesome! That is a work of art! Brings tears to my eyes!

Tomisimo
01-31-2010, 02:21 PM
Ouh nice, now thats what I call fabrication!! Props for that

but I would TIG welded it, not MAG, that way you didnt had to grind it later.
And TIG welds look awesome..
http://i82.photobucket.com/albums/j263/guyhatesmycar/100_1018.jpg

Ichiban
01-31-2010, 08:38 PM
Ouh nice, now thats what I call fabrication!! Props for that

but I would TIG welded it, not MAG, that way you didnt had to grind it later.
And TIG welds look awesome..

Yeah, if the welds looked decent, I would have left them there. However, our shop doesn't have aluminum TIG, and the sides of the runners needed quite a large buildup to create the transition between port and tube.

http://i82.photobucket.com/albums/j263/guyhatesmycar/013-1.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/014-1.jpg

Grinding off all that weld caused a new problem. There's porosity that's causing pinhole leakage in one runner for sure. I put a few tacks on it tonight and ground it off, but it still leaks....And the material is so thin I can't burn in the weld hot enough to float out the contaminants.

http://i82.photobucket.com/albums/j263/guyhatesmycar/011-3.jpg

http://i82.photobucket.com/albums/j263/guyhatesmycar/012-1.jpg

Of course, today I thought I was finished with it so I milled the flange flat again. Took a couple hours because the way I had it held in the vise was, well, the opposite of rigid. The flange was warped about .030" high in the middle, so it took a bunch of .004-.005" passes to get it to clean up.

But now I find out I have to weld on it again.

Rendon LX-i
01-31-2010, 09:35 PM
wow...very nice work. SO this is for John?

Ichiban
02-01-2010, 07:25 PM
wow...very nice work. SO this is for John?

Yap!

New solution: Gonna drill out the pinhole crap and fill it back in with clean metal!

Ichiban
02-16-2010, 04:42 PM
Oh hey I've finished this by the way. John, PM me your address (for like the 9th time, I keep losing it) so I can mail it back.

Oh hey, I'm leaving the brace tacked to the tubes in case you have to move it at all. Once the final length is figured, somebody can tack it in a few more spots, I guess.

AccordB20A
02-16-2010, 09:08 PM
pics of the finished product

2ndGenGuy
02-16-2010, 11:06 PM
Siiiiick! PM sent!

Hazwan
02-17-2010, 04:32 AM
Siiiiick! PM sent!

SICK indeed! And PICS from both of you!!

2ndGenGuy
03-11-2010, 10:54 AM
Got it in the mail. What a work of art. I'm going to put it on display in an art gallery until I get my engine ready to go. I swear, what an amazing-looking piece. Everybody should pay this guy to build custom parts!

Hazwan
03-12-2010, 04:30 AM
Got it in the mail. What a work of art. I'm going to put it on display in an art gallery until I get my engine ready to go. I swear, what an amazing-looking piece. Everybody should pay this guy to build custom parts!

Um you forgot something?

2oodoor
03-12-2010, 05:33 AM
yikes, that had to hurt.. chest punched in..

love the work, keep it up it is getting better and better