Front inlet no go.JPG
86 hits | 63.02 KB | Posted: 10/24/15
This is the way I'd have liked to run the throttle body. Didn't work out that way. Too close to the ...

Front inlet.JPG
106 hits | 85.34 KB | Posted: 10/24/15
Would have looked nicer like this but it fits best facing the passenger side. Oh well.

Raw material.JPG
99 hits | 54.14 KB | Posted: 10/24/15
One block of 1" x 6" 6061 aluminum. Raw material. There's an adapter in there somewhere.

Layout1.JPG
99 hits | 48.98 KB | Posted: 10/24/15
There's a lot of layout work getting to this point but it all comes down to this. Lines on aluminum....

layout2.JPG
90 hits | 55.14 KB | Posted: 10/24/15
Laying out the intake flange side of things. This is an idealized version of the ports. The intake w...

on engine rough holes.JPG
101 hits | 68.18 KB | Posted: 10/24/15
Starting to cut out the ports. Cut out a pair of circles with a hole saw to get a bunch of material ...

rough holes.JPG
99 hits | 75.09 KB | Posted: 10/24/15
Got the straight through section of the ports roughed out. Now to grind the angles in to match both ...

router1.JPG
111 hits | 74.5 KB | Posted: 10/24/15
Used my router with a plunge cuttting straight bit to rough in the first 1/8" of each side. Jus...

router2.JPG
106 hits | 77.9 KB | Posted: 10/24/15
More router work on this side.

roughed in2.JPG
97 hits | 43.05 KB | Posted: 10/24/15
Die grinder with carbide bit got the ports roughed in pretty well. Need to do finishing work on the ...

roughed in1.JPG
96 hits | 42.73 KB | Posted: 10/24/15
The ports are a bit rough but at this point it's a functional piece. Everything else is polish.

finished1.JPG
90 hits | 48.93 KB | Posted: 10/24/15
Finished piece. Intake elbow side. You can see the 5/16"-18 tapped holes for the plenum studs. ...

finished2.JPG
106 hits | 51.61 KB | Posted: 10/24/15
A little work with sanding rolls really cleaned up the ports. Not too shabby. I also ran the router ...

finished studs.JPG
119 hits | 50.07 KB | Posted: 10/24/15
Studs installed. The upper plenum fits it perfectly. I need to cut a gasket for it because Ford used...

finished elbow bottom.JPG
100 hits | 51.93 KB | Posted: 10/24/15
Plenum bolted to adapter. Just a little step here and there. Won't hurt anything.

finished elbow.JPG
97 hits | 47.52 KB | Posted: 10/24/15
The way it'll look on the car. Not too shabby for a guy in a garage with a drill press and die grind...