[Che]

I'm wondering hard how cast alloy is to weld, because if I can i'd like to have this throttle body welded directly to this intake manifold. I do have a DIY adaptor plate, although no plate = more vertical clearance (current setup is rubbing on bonnet underside). But - the cast walls are thin, it'd be hard to poke a tig welder around the joint, and i'm scared that the throttle body may warp slightly enough to become useless.

What do you guys think? Get it done or quit while i'm ahead?

[tanshi]

i personally wouldnt, you would be better off designing a lower profile adapter plate.

[Che]

Here's my problem - i'm getting a little bit of rub on the underside of my bonnet from this point on the air hat.



The intake setup in the first post photo is 15mm lower than in the second pic - put in an adaptor plate and it's taking away a clearance advantage I could gain.

[tanshi]

is there a lip on the bottom of the hat you could trim down.

how thick is the adapter. i would think you could make up a 6mm adapter easy enough.

15mm seems exxessive

[JrZook]

If rubbing/clearance is an issue why not lower your engine by elongating or re-drilling the mounts? Wonder how good those alloy brazing rods would work on this?

[BlueSuzy]

make a 90' adaptor?

[Che]

JrZook wrote:

Wonder how good those alloy brazing rods would work on this?

http://www.muggyweld.com/?view=super5 - looks like the perfect stuff for the job! I'd be game to try that.

I just went to a workshop in Wangara - he said the best idea would be to keep it two piece for ease of repair, to plane off the the cast carby base plate and weld on a new adaptor face. Makes sense - then i'd have plenty of clearance up my sleeve. But, I got the idea he'd rather someone else do the welding... I guess welding 2mm cast alloy isn't exactly childs play. But I've seen enough welding in the last year to know it can be done.

[christover1]

bonnet can easily be lifted a few mm

It also may only be a cross rib catching, which could easily be love tapped or notched

[KEENSY85]

could u dint in on that spot,or cut it and fold the original material back down and weld it back on

[Parry]

Cast alloy is crap to weld without decent heat which will prolly warp it..

[BlueSuzy]

How thick is your adapter now?

[missmyljdaze]

How about devcon or similar?

If you can find a spare manifold and dont mind experimenting- I have a spare tin of the "devcon-ish" stuff we use to glue drill rods to hammers for blast hole drilling.

The "devcon-"ish stuff was so strong it would hold for thousands of hours of use on a drill rig- being hammered continually the whole time.
To remove the hammer or coupling when it failed the fitters would have to heat it up with an oxy torch until the steel of the hammer assembly and drill tube were cherry red- then use reverse rotation to unscrew them.
Even then, quite often the steel drill tube failed before the "devconish" stuff let go.

I reckon if you can find an old manifold- we can do a cut- and - shut and glue it together and see what happens.

If it works- all is good
If it doesnt- well, bung the original manifold back on, and think again.

gimme a call!

Stephen.

[pyrohamish]

Just get the old holes on the manifold filled up and a bit of material added to the sides and tap some new holes for the studs.

[Che]

missmyljdaze wrote:

How about devcon or similar?
...
If it works- all is good
If it doesnt- well, bung the original manifold back on, and think again.

gimme a call!

Stephen.

I have a plan, but two heads are better than one - i'll buzz ya when i'm back. I'll give it a try around middle of the month - work will have me in Exmouth for a week or so in the meantime.

[missmyljdaze]

no worries Tim,

work has me trundling up and down the highway and all over the place- so when you are ready, either text, PM, smoke signals or whatever will do.

stephen

[shakes]

I'd look at the other idea's first, dropping engine/trimming some of the plenum/trimming bonnet/90* adaptor...

Can you get the manifold, TB and adaptor or shaved down a couple mm each?

[fully sick coily]

cut a hole in the bonnet and put a scoop over it

[JrZook]

Wonder how hard it would be to modify the manifold for sidedraft entry like the guys do in the states for the my-side harley carb kits. Flow characteristics would improve nicely over the downdraft stock setup.