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custom intake manifold - welding questions 

 

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 Post subject: custom intake manifold - welding questions
Posted: Sun Feb 13, 2005 6:54 pm 
Getting Side Ways
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im looking into buying an eaton M90 supercharger for my ED, i want to run it off the AC compressor belt, but to fit it onto the intake side of the motor i need to piss off the standard manifold, and go something like the one on the BA XR6T, if i buy aluminum wire for my MIG, will i be able to weld a new aluminum plenum to whats left of the runners on my stock manifold (im going to keep the flange and about 80mm of the runners so i dont have to stuff around making new spots for the injectors and mounts for the fuel rail.

OR will a BA XR6T manifold bolt up to my motor (im not holding my breath on this one)

 

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Posted: Sun Feb 13, 2005 8:56 pm 
Stock as a Rock
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A BA BBM manifold won't bolt up, but an EF-AU one will, and they are the same apart from the bolt positions for the head.
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Posted: Sun Feb 13, 2005 9:04 pm 
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Welding cast alloys, such as the plenum, can be hasrd as you get all kinds of inconsistencies in the material, unlike the blank sheets of aluminium you use to creat the modifications. which will normally be much easier to weld. Can be a tough job, you didn't mention if you are an experienced welder or not.
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Posted: Mon Feb 14, 2005 5:45 pm 
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Wolf, i am a fairly good welder, but ive only ever used MIG or ARC before, im gonna drop into one of the welding supply shops round here and have a chat about welding aluminum with a MIG, if they recon its a go, ill have a try at it.

Aaron, i thought the BA XR6T had a plenum arrangement like the EA-ED but with really short runners? - or maybe im thinking of the nizpro manifold, oh well.

 

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Posted: Mon Feb 14, 2005 10:50 pm 
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Think you need a TIG for alloy welding... Ive apid for alloy welding and it costs alot more than steel to be welded. I made a manifold last year and there was $300 for just the welding
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Posted: Tue Feb 15, 2005 5:11 pm 
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yeh, i decided it was too much effort, then i realised that the nizpro XR6T manifold, was the bottom half of an EF-AU style BBM, (the runner part) with a new plenum on top, i think im gonna go that way (cos i can make a new plenum easy as aout of mild steel).

 

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Posted: Sun Mar 13, 2005 8:52 pm 
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yeh tig wouldav been the go , ive tried it with al before and i m no good so i get the boilies to to it , ill be probably modifieing or building one from scratch later in the year for a 6/71 and im not lookin forward to it
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Posted: Mon Mar 21, 2005 1:15 pm 
Oompa Loompa
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TIG or MIG welding of ally is acceptable but either way you have to have a high freqnecy pulse welder. You can't just use any old TIG or MIG machine. The cheapest welder I have seen with the right functions is around $3000.

TIG welding is generally used because it is neater and give the nice fish scale welds. MIG welding ally is easier and quicker.

Also welding cast aluminium is okay as long as you use the filler wire designed for cast aluminium. The other trick is to make sure the ally is very clean and not oil soaked. If it is oil soaked to need to hot wash it or clean it with a solvent and a wire brush to get the grime out of the pores in the castin as much as possible.
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Posted: Tue Mar 22, 2005 2:37 pm 
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MarkZE wrote:
TIG or MIG welding of ally is acceptable but either way you have to have a high freqnecy pulse welder. You can't just use any old TIG or MIG machine. The cheapest welder I have seen with the right functions is around $3000.

TIG welding is generally used because it is neater and give the nice fish scale welds. MIG welding ally is easier and quicker.

Also welding cast aluminium is okay as long as you use the filler wire designed for cast aluminium. The other trick is to make sure the ally is very clean and not oil soaked. If it is oil soaked to need to hot wash it or clean it with a solvent and a wire brush to get the grime out of the pores in the castin as much as possible.


Someone's done this before! :D
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