homemade intake manifolds

keep on keepin on!
thanks for doing something that you thought up and decided to try,and showin the rest of us how it is going for you.we need more of this.
it seems like a lot of people just want to be told what will work and don't want to experiment to find out what works "best"for themselves.race bikes utilize intakes such as the ones you are making,harley's also use a similar setup.
i for one don't think you will have any trouble after you get them done.i have always wanted to cast some parts,but have to many irons in the fire as it is.
check out chopper daves blog,he is a casting madman.
www.chopperdaves.blogspot.com/
mainly harley parts,but he does have a tl1000.

all right version #5 is done. came out fair and learned a bit along the way the programs are done for the CNC, so i should be able to face and profile on the lathe and then finish it in the cnc, which should take alot of time off making them. i think the pattern i have now will work so i am going to make two more so that i can pour three at once. right now i can pound up a mold in about 30 minutes but if i can do three my production will increase 300% with little more effort!! all in good fun.
pic= left is the GPZ750 right is mine

Ingenious!

Very nice work. Must be nice to have the ability and tools to be able to do this, I'm jealous.

That thing looks great!

oooooooooo!!! version #6 is looking good! pictures will be coming soon

all right, got some of the machining sequence down, the one yesterday took about 3 1/2 hours to make, to day was less than two, whicj is counting making the mold and pouring the aluminum. i like the new pattern i made today so i will copy it and pour multiples at the same time. i am turning two grooves into the piece to give the hose something to "grip" onto. this one has a shallow internal taper, but i need to do the math to get the proper angle for the GPZ to KZ taper. all-in-all i am close to have the steps down

Those look awesome. I wish I had access to the tools you do (and the skill to use them). I've been trying to think of a way to eliminate those pesky rubber boots for a while. If you decide to make some to sell, pm me, I would be very interested. Keep up the great work.

Sarge

My high-school had a mini foundry and a full (but old) machine shop and welding shop. I poured a few molds for various projects with pounding-sand-casts-by-hand method. It felt pretty good when it came out just right.

The school got rid of the shop shortly after. Do any high-schools have that stuff anymore? I guess the U.S. isn't a manufacturer of a whole lot of anything anymore. Too bad. I'm glad I had the chance when I did.

Beautiful work flht!

i am a high school teacher, this is what i am doing with a few students during the pattern-making unit in Metal Fabrication 3. i also have a independant study kid working on a 2 into 1 intake for a newer KZ400 engine. the casting/ pattern-making unit is only about 4 1/2 weeks long and i do not think we will get the 400 stuff done as a class. we are also making some patterns for pedal covers for old hot rod cars. the billet stuff looks good but it is too expensive to experiment with, most of my casting is used briggs and stratton engines and flywheels, but near anything gets tossed in, pop cans and such. these adaptors would require about 2 1/2 of three inch diameter of 6061 is about 10 dollars in material, while casting old engine blocks cost me nothing, but my time.

when i am sitting around home, the wife will ask "what are you writing" then i show her my book and all she says is "Oh your doing that again" everyone needs a hobby i guess. this page is my scribblings for making my programs and just getting the stuff to make sense for me

work looks great!your notebook is probably easier to go back to when you have a question - than the stuff i write in the air with my finger :laugh: .