Bespoke Intake Manifold B202

[Jordan]

Cool. Here is a summary of the info I saw. https://www.roadandtrack.com/new-cars/c ... one-elses/ .

[squaab99t]

I have to say I love this Rhino Cart from Stronghand. The 2” on center holes drive you to make bases and fixtures line up to that pattern. With that you can place your business anywhere on the table. Originally I thought I was going to have to rebuild the fixture to pick up new holes on the other end of the head to get the intake side to face out. This was opposite to the header build.
I moved the rotating clamp and upright to the right side of the table and a few rows in, and bam ready to rock and roll.

DE4FA600-99AC-43C8-BC50-1A7B0FCA161C.jpeg (100.37 KiB) Viewed 4951 times

[KPAero]

Nice bench set up, definitely looks more comfortable then just laying it on the table. I have one of these https://weldtables.com/collections/fabblocks

Not exactly the same quality, but still really nice to have the holes and associated clamps etc.

[squaab99t]

I was looking at those prior to choosing the Rhino Cart. It is a good looking system and reasonably priced. I do like the fact you have a vertical plane to build off of.
The rhino cart and clamp starter kit I got 20% off and free shipping.

On to the manifold, Working on the runners and trumpets.

[squaab99t]

A state of independence on the 4th weekend Working on the position and fixturing of the plenum back plate, trumpet, and tubing routing.

[squaab99t]

More work on the tooling. Took the sag off the unsupported tail of the head. Built a jackscrew strut to level with the table.
Adding an index feature to locate the plenum trumpets face plate. Still needs a few more members, but that is the idea.

[KPAero]

Looking good, I imagine this will be well worth it when it comes time to start tacking things together to keep everything where you want it.

Where are those squares from?

[squaab99t]

Got the squares from Fireball Tools. They were a Diy precut weld up kit. His cast aluminum and iron ones are really nice.

[squaab99t]

The plenum back plate is now fixtured to the head. Need to add some indexing pins, but the squares and majority of the clamps are gone.
Trumpets and runners are on deck.

[squaab99t]

Glad to see the site backup. More fitment work to get the tubes in their happy spot.
Index pins so I can remove and replace the plate back to it's original location.
Mandrel tool and dead blow to true up the shape and inner dimensions to match the intake flange runners.
Introduced the mock-up plenum for entertainment factor. Not sure I will stick with that design?

I have had an old weld position-er for sometime, time to do some coupons and then get after the real deal.

[squaab99t]

Doing some positioner (rotory table) prep, coupons, practice and dialing in.
Set the height of the machine and hand rest location.
Made a centering fixture to index the trumpet and mini hold down clamps. This will allow not only pushing filler rod keeping the part in place, but a horizontal position, if that plays out a better bead.
Ran three fillet coupons for practice. First one was pretty awful. Too fast and too cold. Third run was very nice. More practice in store before go for real.

[squaab99t]

Rolling out some dimes.

[squaab99t]

Runners are tacked and it is now freestanding. Now to figure out the welding sequence and any preheat.

[squaab99t]

Money shot.

[squaab99t]

Practice to dial in the speed of the positioner, rest position bars, amps, and radiate heat.
Makes a big difference with the speed. Too fast and not enough penetration and the filler rod does not take. As seen by the first picture. The part was rotating counter clockwise.