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oldopelguy · 03-19-2004

With my own dubious skills welding aluminum, I think I'd probably introduce a lot of warpage to the manifold if I wee putting in a large piece. I think I would make a pair of inverted "V" incisions in the manifold, one on the inside edge closest to the head and the other opposite it on the outside edge. These could be made with any small cut off wheel, and ideally you'ld drill a hole clean through from one side to the other to locate the three points.

Once you had the 2 cuts made, a folded piece (or 2 flat pieces) of fairly thick sheet aluminum could be slid into the one side and through the plenum to come out the other, giving you your pent floor inside the plenum. Then you could weld in the piece in place to seal it on the outside of the manifold, where it would be fairly easy, and with the floor intact the warpage should be minimal. Also, if there were pilot holes drilled at the corners, the porting around and under the piece would be unnecessary, as it would slide through no matter what was underneath.

For you guys without aluminum welding facilities, depending on how close you kept the tolerances you might even be able to epoxy the piece in place. It's not being a structural element, after all, all you're doing is sealing the edges.

My $.02, and yes I'll try to photoshop a picture to explain it better as soon as I get my new camera working if anyone is interested.

03-19-2004	#61 (permalink)
oldopelguy Have Opel, Will Travel Join Date: Mar 2002 Location: Pickens, SC Posts: 1,595 Classified Rating: 0% (0) Logbook Entries: 3	not the bottom With my own dubious skills welding aluminum, I think I'd probably introduce a lot of warpage to the manifold if I wee putting in a large piece. I think I would make a pair of inverted "V" incisions in the manifold, one on the inside edge closest to the head and the other opposite it on the outside edge. These could be made with any small cut off wheel, and ideally you'ld drill a hole clean through from one side to the other to locate the three points. Once you had the 2 cuts made, a folded piece (or 2 flat pieces) of fairly thick sheet aluminum could be slid into the one side and through the plenum to come out the other, giving you your pent floor inside the plenum. Then you could weld in the piece in place to seal it on the outside of the manifold, where it would be fairly easy, and with the floor intact the warpage should be minimal. Also, if there were pilot holes drilled at the corners, the porting around and under the piece would be unnecessary, as it would slide through no matter what was underneath. For you guys without aluminum welding facilities, depending on how close you kept the tolerances you might even be able to epoxy the piece in place. It's not being a structural element, after all, all you're doing is sealing the edges. My $.02, and yes I'll try to photoshop a picture to explain it better as soon as I get my new camera working if anyone is interested.