basically got a upper inlet manifold (not ford) thats been made simply out of 4mm Mild steel box section for a project, got all the bits to do it bar the actual cutting out of the ports for the lower inlet which bolts to the head

tried a few companies locally, but they can cut the ports, which are oval, which match up to the lower inlet (got a gasket as a guide for it)

as they reckon plasma cutting wont work ?, and to cut them out manually is going to be a nightmare ?

any ideas

jr

 

4 mm wall steel box! What you building a tank?

Draw the shapes on and the use a series of drill holes around the egdges and then file to final shape.

Or...

Ditch the heavy steel bit and get a nice ally bit knocked up. Could be welded on then.

 

it might not be 4mm, it could be 3, problem is people have made these before and when tightning them down on the lower inlet they have deformed on cheap/thin versions

if it works there will be an alloy one, just need to try this first

had considerd the drilling holes and filing them, but thought there might be an easier/neater way

 

Drill the holes and then use a die grinder / deremel. Beats a hand file any day.

 

Have it lazer cut, take your gasket with you and they will draw it up on CAD, i live in the arse end of nowhere and there are 3 companies within 20 miles of me that do it, so where you are you shouldnt have much trouble

 

Mark out shapes, drill as big a hole as possible but smaller than the port size, then hit it with the die grinder fitted with tungsten carbide cutting tool. will rip through in no time most sheet metal firms can do this