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Old 12-27-2005, 05:29 PM   #1
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Cool Manifold Idea.. want opinions

In the never ending battle of the cracking manifold I have had an..... what I think is ..... a good idea!!!!

Before I go any farther I want to say that its NOT Toms fault about the cracking. The intake was designed for an NA car ... and well.. I'm boosting the crap out of it so its going to break.... but thats also real good R&D!!!

The problem is flex in the manifold, like when you run 19psi of boost... let off the gas and it goes to 20-27 inches of vaccum which ends up in flexing the shit out of the manifold.

My idea.....

Fix the current crack... which is fairly small... right now its a hairline crack.
After getting it welded and getting it back, clean it up real good, get some industrial strength resin and cover everything except places like the TB flange, IAC flange, ect with some high quality CARBON FIBER mat.

Do you guys think it would be strong enough to really cut down on the flexing issue???

I know it'll be a couple or so weeks until the new one is done, so this would be something to get by on.... plus I think it would look really cool.....

A Custom made intake manifold coated in a carbon fiber resin.... that would look so sweet

BUT will it work???

John


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Old 12-27-2005, 07:23 PM   #2
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make another intake out of thicker sheet metal
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Old 12-27-2005, 08:04 PM   #3
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I got my intake installed last sunday,it is a custom made short runner with velocity stacks and all, let see how it goes, I'd post some pics but I don't know how.
I'd think that you already have to much metal the problem with welding again and again is that the metal keeps getting stressed and will keep cracking.
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Old 12-28-2005, 11:49 AM   #4
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i realize this isnt a ford but i figured maybe you would want an idea. oh and this is 100% carbon fiber, not overlayed. i think you should be shopping for a cast intake manifold.
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Old 12-28-2005, 05:43 PM   #5
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That most be expensive.
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Old 12-28-2005, 06:34 PM   #6
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I dont NEED to shop for a different manifold... as stated in the first post this is to hold me over until the stage 2 prototype is ready. Its going to be built just for BOOST.

Anyways, I ground out the crack alittle bit today, angled the walls of the crack and filled the little bastrad full of JB Weld INDUSTRIAL ... actually it doesn't look bad at all.

It must have fixed it... my high idle problem went away. I'm gonna let it set with some warmth on it until tommorrow night before I drive it anywhere..

OH, it was just a hairline crack about 1.5 inches long.... this should have done the trick PLUS I'm gonna drop the boost from 19 to 10psi... just incase


One maore thing.... DAMN that Honda's intake looks nice...
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Old 12-28-2005, 07:17 PM   #7
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...Crack in the same spot??
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Old 12-29-2005, 07:01 AM   #8
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Nope, in a different place

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Old 12-29-2005, 09:00 AM   #9
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Stress crack from vibration?? Where is the weight supported and how? where was last crack?

Nice pic by the way, you'll have to tell me how to post one day...
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Last edited by finalley; 12-29-2005 at 09:08 AM.
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Old 12-29-2005, 11:01 AM   #10
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We think is from the constant boost->vaccum->boost->vaccum

Basically its just flexing the shit out of it, causing stress cracks.

The last time... in the same pic from above.... you can see the black marker lines across the bottom then up the arch on the left side..... I blew the shit outta that thing at VIR LOL
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