Custom Sheet Metal Intake Manifold for Boosted and Nitrous Oxide Use - Chevy Cobalt Forum / Cobalt Reviews / Cobalt SS / Cobalt Parts
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post #1 of 21 (permalink) Old 06-07-2010, 08:50 AM Thread Starter
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Custom Sheet Metal Intake Manifold for Boosted and Nitrous Oxide Use

I am finishing up with my intake manifold (i still got to weld the flange on and grind and polish it) tell me guys what you think about it, manifold it self is a (3 inch wide, 11 1/2 inch long ) is it to small?/too long?/is it enough volume, if the runners( 1 1/2 inch wide, 4 1/2 long) are too long/to short/too wide? any criticism or notations will help.... also what kinda stuff should i spray inside to keep it from rusting maybe some kinda silicone, plastic or ceramic paint or what ever

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post #2 of 21 (permalink) Old 06-07-2010, 10:07 AM
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Send it off to get ceramic thermal coated. Should take care of the inside and outside.



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post #3 of 21 (permalink) Old 06-07-2010, 10:11 AM
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I like the effort. but...

($aftermarket < $homemade +risk) ...something so key in the engine and N2O injection seems like quite a gamble. BUT I know nothing of welding, so if you feel comfortable...it looks pretty slick man, if it works out I'd love to see the finished product.

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post #4 of 21 (permalink) Old 06-07-2010, 10:53 AM
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looks good but clean up those welds a bit

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post #5 of 21 (permalink) Old 06-07-2010, 10:54 AM
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well you should try mig welding with gas...aka no flux core wire. the runners may be a little long, nothing to worry about though. i think you should just buy the log manifold and save yourself the headache man. i know the gratification when you build something yourself but this is the kind of thing aftermarket manufacturers take a long time designing/building with lots of flow testing and such. good luck you got the right idea!

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post #6 of 21 (permalink) Old 06-07-2010, 11:10 AM Thread Starter
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Originally Posted by stickx911 View Post
I like the effort. but...

($aftermarket < $homemade +risk) ...something so key in the engine and N2O injection seems like quite a gamble. BUT I know nothing of welding, so if you feel comfortable...it looks pretty slick man, if it works out I'd love to see the finished product.
lol don't worry there's no risk cause it's metal i already got sick of wondering if that plastic manifold will be blow out every time i shot nitrous oxide besides its almost the same as hahn intake it's just i made this one for $60 including all the fittings for vacuum/boost gauge, brake booster and other two lines the hahn one is $700+ comes without fittings its looks like up to quarter inch aluminum TIGged together so it might actually weight even more then my intake but yes before i post a DIY i will test it out just to make sure that i am showing you how to do it right and it won't damage your engine

---------- Post added at 11:10 AM ---------- Previous post was at 11:06 AM ----------

Quote:
Originally Posted by ff_drift_lol View Post
well you should try mig welding with gas...aka no flux core wire. the runners may be a little long, nothing to worry about though. i think you should just buy the log manifold and save yourself the headache man. i know the gratification when you build something yourself but this is the kind of thing aftermarket manufacturers take a long time designing/building with lots of flow testing and such. good luck you got the right idea!
i know MIG works so much better but i need a torch for it and a regulator :(

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post #7 of 21 (permalink) Old 06-07-2010, 11:14 AM
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i do most of my welding flux core cause i always run out of argon, but when it comes to stuff like this i always use gas. like my coilovers, i used gas to make nice clean welds this way no one questions them when i get the car inspected. you can make them nice with a grinder, but there will always be air pockets weakening the shit out of the welds and leaving lots of room for leaks. tig welding might be heavy, but its because there's no air pockets and it's a thick sturdy weld.

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post #8 of 21 (permalink) Old 06-07-2010, 12:42 PM Thread Starter
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i do most of my welding flux core cause i always run out of argon, but when it comes to stuff like this i always use gas. like my coilovers, i used gas to make nice clean welds this way no one questions them when i get the car inspected. you can make them nice with a grinder, but there will always be air pockets weakening the shit out of the welds and leaving lots of room for leaks. tig welding might be heavy, but its because there's no air pockets and it's a thick sturdy weld.
o i am not talking about heavy or bad welds with a TIG i was saying that on the hahn intake they used a quarter inch aluminum plating and that could be heavy lol i'd love to TIG weld an aluminum intake manifold but i would use a bit thinner metal, yea dude i got your point i did find out that if you put flux on high with wire speed on 4 that makes pretty nice clean weld without any air pockets well i will grind it seal the runners and throttle flange and put a water house in it turn the water on and little water streams will indicate where the leaks at (i learned that from " how water heaters are made") bahahaha

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post #9 of 21 (permalink) Old 06-07-2010, 01:32 PM
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cool man, i can't wait to see the final product. keep us updated!

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post #10 of 21 (permalink) Old 06-07-2010, 02:08 PM
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welds look like shit




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