Sheet Metal Intake Manifold.

[tauruck]

I need stirling advice on a sheet metal intake.

I used a brand new Torker11 manifold from Edelbrock to create a welding jig
for the Aluminum plates (3) I'll be using to make up the base.

I have two options.
Use the jig that by all accounts is accurate and has all the threaded inserts built in already
or take the dummy block with the heads mounted to my Aluminum weldor?.
The thing that bothers me is that the welded jig might be a small amount "off" due to the welding.
Using the block and heads means wasting a set of gaskets and the transportation is going to be difficult.

When making the jig I used 6mm steel plate and never welded it all in one go.
I took my time and used the original fasteners to set it up.

[SPARKY]

When I bought my first profiler manifold I couldn't find one for a std. height  BBC block---they had to mill the tall deck intake manifold to fit the head and block.

you might take the same approach build the manifold slightly to "small" with thick flanges and mill to fit---it would also take care of any welding induced warpage at the same time.

[Dynoroom]

Mike, do yourself a favor and use the block & heads for mockup to weld. It WILL warp some. so be ready to mill the flanges if needed.

[tauruck]

Thanks Mike.

Do I set it up with or sans gaskets?.

[SPARKY]

My vote --  set it up with thick flanges and no gaskets so you can mill to straighten and fit

[Peter Jack]

I'm agreeing with Sparky. 

Pete

[tauruck]

Thanks Sparky and Pete.

Wise words. That's exactly what I'll do.
Awesome advice.

[tauruck]

I was just thinking that I'll need to use head gaskets and tie down the heads
properly so I get correct bolt alignment.

[SPARKY]

I was referring to intake gaskets

[tauruck]

I was referring to intake gaskets

I know you were but if I leave the head gaskets out it will change dimensions fairly drastically.

[Ron Gibson]

Head gaskets come in a variety of compressed thickness's. Also that gasket dimension can change your compression ratio substantially. You need to figure out which ones you are going to use. Then you could use shim washers of the right thickness,under the head on the bolts so you can clamp them down tightly for stability without using up new gaskets.

Ron

[Dynoroom]

Ron is correct, you should use either a head gasket or simulate one. The bolt them down with 3 or 4 head fasteners. No need to use them all or torque to spec. Using a new head gasket is not a problem, most will be ok to use afterwards.
Carry on...

[tauruck]

First problem encountered.

I have an ARP bolt kit for the original Torker2 manifold.
Instinct tells me the bolts are a little long for my sheet metal application.
Do I replace them all with shorter High Tensile good grade bolts?
I could swap out some of them but that's looking for trouble IMO.

Thanks in advance.

[tauruck]

Some pics of the original fasteners from ARP on both ends.
The bushings look very long. What say you guys?.

[Dynoroom]

Swap them out, no problem. The use of grade 5 in this application is fine.