Monday, October 6, 2008

Building an Intake Manifold

After getting the Monster Carb in the mail on Friday, I set about building an intake manifold for it. I had sketched up various ideas, and settled on a system design I was hoping I could build at home, without needing to outsource all the fun work.

The concept uses two large washers, one for the flange that connects to the cylinder head, and one for the flange connecting to the carb, connected with a section of curved pipe massaged to fit the proper openings of the head and carb. With washers and pipe in hand (and a cold beer for refreshment,) I got busy.

Washer on left fits cylinder head, washer on right fits to carb. Note that carb mounting holes are slightly off centered "up and down" in relation to the center hole:



Center pipe section is cut from a conduit sweep. I cut four little "pie sections" out of the cylinder head end so the pipe could be made slightly smaller in diameter to fit smaller intake port opening:



Small end of pipe was formed, welded, and ground smooth:



Freshly welded intake, ready for high heat resistant paint, followed by a good wrapping of exhaust header wrap for better thermal properties:



Carb mounted on intake. Intake bolts are threaded into the flange, which was tapped before painting:


Overall, this was a fun project to work on, and is sized to work with several typical small Mikuni carbs, which all have slightly different flange bolt patterns. I also made a second set of flanges, and have enough of the conduit sweep remaining to build a second complete manifold.

C'

1 comment:

Sara said...

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