Thread: building a sheet metal intake questions

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i have alot of aluminum laying around and am going to build a sheet metal intake for 2-4500 series throttle bodies with injector and nitrous bungs, anybody ever tried this before? I have a miller synchrowave 250 dx ig rig that has been sitting to long so i better fire it up and see what i can do, i am also going to polish it and have it chromed because a fabricated manifold with those beautifull welds polished and chromed looks soooo good along with the 2 billet polished full throttle throttle bodies on will look killer, but if it doesn't work all i will be out is about $20 in scrap metal and some fun trying right? been doing alot of research on them but any info would be awesome, tube sizes , taper, angle from top of engine plane to top of intake plane, plenum volume.........

Originally Posted by gottabuild1

i have alot of aluminum laying around and am going to build a sheet metal intake for 2-4500 series throttle bodies with injector and nitrous bungs, anybody ever tried this before? I have a miller synchrowave 250 dx ig rig that has been sitting to long so i better fire it up and see what i can do, i am also going to polish it and have it chromed because a fabricated manifold with those beautifull welds polished and chromed looks soooo good along with the 2 billet polished full throttle throttle bodies on will look killer, but if it doesn't work all i will be out is about $20 in scrap metal and some fun trying right? been doing alot of research on them but any info would be awesome, tube sizes , taper, angle from top of engine plane to top of intake plane, plenum volume.........

If you don't own a flow bench or have one right next door you are just wasting your time.

why is that? the top sheetmetal intake guys have no flow bench, call sonny's and ask them

if all you will have is 20 bucks and your time then go for it. as far as asking other people for their secrets. those are very close guarded secrets that those builders will take to the grave. i bet sonny has one he is just not saying so. if not hes pulling lots of engine dynos for info, either way he is checking concrete data in his programs, but ya 20 bucks go for it!!!!!!!!!!

That is my exact thoughts, if it don't run for s--t i will have an awesome looking garage ornament

Wheather or not you have a flow bench, it will probably run just fine for street use, and if you're more about the "awesome look" than a measurable horsepower gain, then go for it. Unless you are going "balls to the wall' drag racing, a polished, handbuilt intake will certainly wow the troops. I'm not sure why you would polish it AND chrome it, but if that floats your boat-----

I'm quite sure Sonny's flow checks all his heads and intakes, here's an ad from his site


GM Hemispherical Heads
Designed and Fully CNC Machined By Sonny's
Home About Us Engines Induction Heads Accessories Apparel Ordering Customers
2007 SAR/BRODIX BB-5 400 CC OVAL MAX FLOW HEADS



At SAR all head porting is done in house. We use a state of the art 5 axis CNC vertical machining center, which can produce precision work to programmed "blue print" specs.

The BB-5 heads are the largest intake port BBC head castings, with raised port aluminum cylinder heads recommended for 565 cu. in. and larger engines, with capabilities of sustaining 600 + cu. in. Other features include replaceable step bronze guides, 2.350" x 1.900". Custom Sonny's heart shape chamber design is also incorporated in this cylinder head.

* LABOR

• CNC machined castings

• Install/fit bronze guides

• Machine for larger valves

• Precision, multi-angle valve job and equalize seat depth

• Full competition port, polish and flow test

• Hand contoured by one of our cylinder head experts

• Machine for Vasco-Jet springs and teflon seals

• Mill for compression

• Pressure check

• Correct spring height and assemble

•

•

PARTS

• Manley "Severe Duty" stainless steel valves

• Manley titanium 10 degree retainers

• Manley 10 degree hardened locks

• Manley hardened spring cups

• Manley Vasco - jet springs

• Manley 8740 rocker studs

• Comp guide plates

• Teflon valve seals

• 11/32" bronze guides

• Chamber volume 113.5 cc

• In. runner vol.: 400 cc

• Ex. runner vol.: 149 c.c.

• Peak in. flow: 445 cfm @ .900” lift

• Peak ex. flow: 311 cfm @ .800" lift with 28" H20
Fully race prepared CNC ported castings $4,075.00
Race ready fully assembled heads $4,920.0

Sonny doesn't have or use a flow bench, sure does have a lot of flow numbers in his ads!!!!!!

there is abit more to making a intake .sounds good but you need to buy or cut out the intake plates or you could buy some tall deck intake spacer plates for the ports alignment then you will have to work on the runner length and the the size of the plenum and were you want the carbs to set will tell how long the plenum will be .you can copy a old intake for size of runner this would get you close. you have to locate the angle and make the boss for the dist you need the block and heads for mock up and the intake can get flowed with it on one head. some of the intakes i work on they use A B putty in the runner and the inside of the plenum .not trying to tell you not to do it but you will have alot of time and money in it then you think

I am sure i would have more money in it than i think just like everything else, i have seen alot of guys build intakes but more towards boosted applications

Also i do know a couple of people with sheetmetal intakes that i can get alot of dimensions off of, one is a sonny's and the other is a Wilkerson here is a pic of one that i really like, imagine that polished to perfection and chromed

Also i do have access to free cnc machining at my brothers shop for th carb plates etc.

man thats gonna take alot of rpm's to get into the powerband with that one pictured, but yes it would look very cool polished up, or just as it sits. well its set you talked me into it, get up saturday morning and get started on it, and post pics please.

i am buyin an intake for my motor just for a single dominator, but it will be fun building it

Great intake in the pic!!! It'll work great at 8,000 RPM setting on top of an 700 cu. in. IHRA pro stock engine!!!!

Originally Posted by Dave Severson

Great intake in the pic!!! It'll work great at 8,000 RPM setting on top of an 700 cu. in. IHRA pro stock engine!!!!

that intake is for Big Chief heads ford killer heads