OutcastZeroOne Posted December 9, 2005 Report Share Posted December 9, 2005 Hey guys, I know a lot of us are wanting to make custom intakes and exhausts, but I know some of us are a little reluctant to cut up our stock parts. I have a few sources that might be able to laser/machine some stock flanges for the intakes and exhausts but I would like to see if there is any interest in this. Let me know. I would make them to the size of the gaskets to get the better airflow. Quote Link to comment Share on other sites More sharing options...
redrocketTSI Posted December 9, 2005 Report Share Posted December 9, 2005 I would be interested. Quote Link to comment Share on other sites More sharing options...
artinist Posted December 9, 2005 Report Share Posted December 9, 2005 see if you can make some aluminum intake flanges with some kind of a water neck. shelby already has awsome exhaust flanges for $40 Quote Link to comment Share on other sites More sharing options...
artinist Posted December 9, 2005 Report Share Posted December 9, 2005 the new flange should be 3/8 Quote Link to comment Share on other sites More sharing options...
Minagera Posted December 9, 2005 Report Share Posted December 9, 2005 I would be down for an aluminum intake flange, 3/8s to 1/2 inch thick. Quote Link to comment Share on other sites More sharing options...
redrocketTSI Posted December 9, 2005 Report Share Posted December 9, 2005 me too. Quote Link to comment Share on other sites More sharing options...
slowquest Posted December 10, 2005 Report Share Posted December 10, 2005 me too Quote Link to comment Share on other sites More sharing options...
kaseobeer2585 Posted December 10, 2005 Report Share Posted December 10, 2005 id be up for an intake manifold flange Quote Link to comment Share on other sites More sharing options...
tsi1987 Posted December 10, 2005 Report Share Posted December 10, 2005 ex in stainless steel 3/8 inch would be nice michael 8) Quote Link to comment Share on other sites More sharing options...
mandoknight Posted December 13, 2005 Report Share Posted December 13, 2005 I would be in for either 3/8 or 1/2 aluminum intake flange, Or 1/4 inch stainless. let me know. what you can do and how much.thanksChris Quote Link to comment Share on other sites More sharing options...
cashsaudio Posted December 19, 2005 Report Share Posted December 19, 2005 let me know about the SS 304 is this the srongest SS? me and my bro gonna try to make a SS header design for my car. All i've seen is just steal rather have SS because wanna make my motor shine up. Jeff please pm me thanks Quote Link to comment Share on other sites More sharing options...
smog Posted December 19, 2005 Report Share Posted December 19, 2005 I believe 316 is common ss material for a stainless flange, then 321 for the tubing. Quote Link to comment Share on other sites More sharing options...
ZPI28 Posted December 23, 2005 Report Share Posted December 23, 2005 let us know.. Steven Quote Link to comment Share on other sites More sharing options...
tsi1987 Posted December 29, 2005 Report Share Posted December 29, 2005 hear anything yet :?: michael 8) Quote Link to comment Share on other sites More sharing options...
cashsaudio Posted December 30, 2005 Report Share Posted December 30, 2005 keep up with the good work:) Jeff Quote Link to comment Share on other sites More sharing options...
Minagera Posted January 3, 2006 Report Share Posted January 3, 2006 I want an intake flange man. How is this payment system working? Quote Link to comment Share on other sites More sharing options...
tsi1987 Posted January 4, 2006 Report Share Posted January 4, 2006 I am in for intake, put me on da list michael 8) Quote Link to comment Share on other sites More sharing options...
Chad Posted January 4, 2006 Report Share Posted January 4, 2006 some ideas to make this more viable for you and your customers: make the headder flanges out of 3/8 1018 cold rolled steel, it's less than 1/2 the cost of stainless, and easy to weld. It's plenty strong for flange material. It also warps less when you weld it. Make the ports 1.900" ID so you can use pipe elbows, the elbows can pass though the hole for a smooth transition. They can also be welded on both the head side and turbo side of the flange for added strength. Make the intake flanges in 3/8" aluminum, it's easier to weld as it requires less heat (aluminum this thick requires some pre-heating). Offer a steel intake flange in 1018 so those with just regular MIG's at home can make a steel intake with inexpensive steel mandrel bends. 99% of buyers will not need/want those EGR/jetvalve holes, and by giving them the holes, you are adding to the work required to use the flanges. Those who do want the holes can drill them themselves using a gasket for a pettern. On the EGR and jet valves, cut the holes in a standard pipe thread diameter so you can just tap the holes and go. Quote Link to comment Share on other sites More sharing options...
Chad Posted January 5, 2006 Report Share Posted January 5, 2006 on the larger ports, I ment the headder only, all 1 1/2" pipe elbows are this 1.900" OD size. On the deletion of intake ports, just the EGR an jet valve, both are small round ones. on the turbo flanges, there are several mitsu sizes, and several less common garrett varriants (T25/ T28, etc), but most are just T3 or T4. there are also devided housing flanges in T3 and T4, but 99% of people won't need them devided. you can get these fairly cheap on Ebay so you may not be able to make any $$ on them. You could offer the mitsu flange though, that one is not made cunnently. Quote Link to comment Share on other sites More sharing options...
Chad Posted January 5, 2006 Report Share Posted January 5, 2006 I respect your dads acomplishments and all, but I've made about 15 custom intakes, and FIP has made nearly as many, of those ~30 or so intakes neither of us have ever provided the EGR or jet valve ports, and no one has ever asked me for one. Same for the Austrailian magna intakes, those don't have functional EGR or jet valve ports either, and I know I've done about 30 of those and Glen about 40, so there are another 70 intakes with out them, most of them currently in use today. "3/8-16 for the EGR and 5/16-18 for the coolent" those are bolt threads, not pipe threads. You probalby want 1/4" NPT for the jet valve and 3/8" NPT for the EGR. There is only one water passage between the runners, it's the rectangualr one between 3 and 4. the ones between 2 and 3 are EGR (large) and jetvalve (small). Putting thse ports in will add to the time and thus cost to the plates. Do as you wish, I'm just leting you know most won't want it, let alone want to pay for it. On the exhaust, they need to be 1.900", that is larger than 48 mm (48.26). larger by .010" , that's enough of a difference to make the pipes not pass though the flange. You can always go oversized a little bit, but underszed will be a problem. It's a good thing you are doing, I hope to see it turn out a nicley as possible. Quote Link to comment Share on other sites More sharing options...
Chad Posted January 5, 2006 Report Share Posted January 5, 2006 It's totaly up to you on the EGR/jet valve ports, I'm just saying 99% of the buyers won't use it, so best not to include it, or the time it takes to cap them. Cool on the port dimensions, I just hate to see a port be .010" too small so I was making sure. Quote Link to comment Share on other sites More sharing options...
Chad Posted January 5, 2006 Report Share Posted January 5, 2006 Yes, the rectangular one between 3/4 is nessesary Quote Link to comment Share on other sites More sharing options...
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