Sheetmetal intake for 383ci clevo.

[xe5800]

Here are some pics of my first sheetmetal intake i made, will update pics because there are more in the build process on my phone.
So when i get time i will do that.
Im new here, found this by accident ,gonna be a killa forum once the word keeps spreading.

[xe5800]

Like most people this is just a hobby of mine. i work at or local sugarmill and employed there as a fitter/welder.
I did my trade as a engine builder(fitter machinest) but my love is fabricating stuff and tig welding aluminium stuff.
I also kept my little superflow bench and port heads also , everything i do has evolved from getting in and doing it for myself
the formal training was good but u dont need it if you are keen and listen to the right people.

So now i have found a spot for my projects u will see alot more from me. til then.
Keep fabbing

[TheFabForums]

Very nice work, I love it.

Do you allow a little space under the front and rear plates for gaskets or do you just use a liquid sealant?
What thickness aluminum do you use?

Welcome to the forum from the other side of the world. 
Loooking forward to seeing what kind of projects you have to post.

[xe5800]

Yeah i try and make the fit as close as possible so that when i put intake gaskets on there it sits up a little on the front and back in the valley area.
 Yes i just run a bead of industrial type silicone front and back never use the shit cork gaskets they always end up weaping down the track or sucking in.
On the intake flange plates i used 10mm flat bar i had laying around.
The runners ,and plenum are made from 5000series 3mm.
The plenum flange and the top plate are made from 5000series 8mm (think from memory it 5051).

As you can see on the intake to runner flange my tig didnt have enough grunt to weld it nice. Thats why it looks cold, even with preheat ,not real happy about that but next time will be better. When i welded it it was bolted to the head which made it like just over 25mm thick and i only have a 200 amp tig ,another 20amps or helium my have got me out of trouble there, but obviously they were not availible.

[charged87]

WOW great job!

[ISL33P]

Very nice work and great to see another on here and doing some quality fabrication...something to look up to.

I have discussed the sourcing of helium with BOC and they can supplly a pre-mixed bottle, approx 35% helium, just need a couple of days to get it in from head office.

Ariel

[CustomTanks]

Great looking work

[xe5800]

Thanks a bunch fella's

[DaCajun]

Man that's beautiful!!! I've always liked Cleavland engines, it's nice to see'em still being built. I gotta say I so jealous of you guys building ya'lls own intakes. I'm going have to make an attempt at that one day. Thanks for sharing your process. Very inspirational!!!

-Dave

[xe5800]

Man that's beautiful!!! I've always liked Cleavland engines, it's nice to see'em still being built. I gotta say I so jealous of you guys building ya'lls own intakes. I'm going have to make an attempt at that one day. Thanks for sharing your process. Very inspirational!!!

-Dave

No Trouble  DaCajun , love sharing stuff with people that could use the info ,pics etc.
love this forum cant wait til it gets bigger, all in good time.

[tininjun67]

 absolutely disgusting fab skills dude. That thing is pure eye candy.  awesome idea for bending the al. into runners!  are you using 5356 rod?

[xe5800]

absolutely disgusting fab skills dude. That thing is pure eye candy.  awesome idea for bending the al. into runners!  are you using 5356 rod?

Thanks bud. Yeah i do use 5356 mainly use 3.2mm rod ( depending on the material thickness)i like to get it hot and use the rod to keep the heat in check a little.

[TwinTrouble]

Intake looks totally rad!  I have a few questions as i am getting ready to make my runners in a week or two:

1) what thickness AL, are you using, .125?  I hear that .90 is ok too, any input?  this will be a boosted motor.

2) What machine are u using to weld your intake?  It looks amazing!  I hear ya on the heat issue welding the flages, happens to all of us with smaller machines.  I have a synchrowave 180 in my shop and access to a sine wave 300amp dial-a-arc at a buddys shop.  I think 200 amps would be enough with some preheating, but im worried that i wont have good enough arc control with a transformer machine.  I think a 200 amp inverter machine would do the trick no problem.  So my question is, what kind of machine are you using?  i am trying to decide if i should use my synchrowave, the dial-a-arc, or just to rent a dynasty 200/350 for a week.

Thanks in advance!  Your work looks amazing!

-Shaun

[xe5800]

The thickness is 120" or 3mm for the runners and plenum.

The machine im using is a token tools 200amp ac/dc inverter pulse jobbie. it has plenty of grunt but couldnt weld the runners to the flange nicely. i pre-heated it still no good. the problem was the flange bolted to the head made it over an inch thick so with straight argon it was not ideal they say a mix of argon\ helium is the go but im yet to try it.
My new shed at home getting built has three phase power so might go a bigger unit

Im no master by any stretch, but will get better each one i do.
Check out marcella manifolds he his the ob1 of intakes.
As long as your welds have good peno boost should be ok. maybe a little burst panel to stop the backfires from killin the manifold.
hope that helps. Good luck with it, be sure to post it up.
Troy.