FWIW question/idea... What if you take a bare block and bolt on a set of heads. Machine up your intake to head plates and bolt them to the heads. Then securely clamp the center section of your intake to the block and try welding the stuff up that way... Would it work? Just curious as Ive tried TIGing alum and I learned real quick that its an art (and that I suck at it). Just a thought..
I am with you on that. 2 problems I had. (granted I am still a rookie).
1. The block is assuming you have gaskets. If you weld it up without gaskets, when you add them, port locations change, and do not line up correctly.
2. To weld the intake I have had to preheat it.
- Oven isn't big enough to hold complete engine
- I am not THAT strong
If I was to heat then bolt onto engine, by that time would lose most of heat.
I have SINCE made a new jig though, which solves all this problem. Only thing is doesn't fix old manifolds, although it did help with some heat.
I am very close, and suspect it will be on the truck within 2 weeks. Tonight going to do some final welding on it, then having a guy machine the surfaces flat.
Intake #3 should have all these problems solved. Of course I do not want to start #3 until #2 is on, and possibly #1.
I can say I have learned a lot... and luckily #2 came out better than #1.. maybe #3 will be GREAT.!!!!
Now the test will be to see if it actually helps performance. I have gone over theory 1000x in head, but until the zr1 hit the road I won't know. First task is going to be passing emissions, since tabs expired in Dec. O' FUN!
