Welding project

[matt]

If some remember, about six months ago I bought a used Miller Dynasty 200DX off a drag racer here at work.  It was a great price and included everything including the filler rod.

Well haven't played with it much and have done a few jobs using it. 

Fast forword, he comes up to me and asks me if I am interested in building a manifold for his car out of aluminum.  I do not understand why, he has a sheetmetal one on his car now.  Wants to save weight, 15 lbs versus 32 lbs.

So I will post some pics as the project goes along.  Got about 6 hours into it so far, that is just welding up the runners.

Here is a picture of the steel one.


Picture of the runner tappered in both directions



A little rusty



Getting better



Here is how they will be on the car

[matt]

A picture of the jig, tapered in both directions.

[M4wdFab]

no off the shelf options?

sounds like a ton of labor, materials, and consumables for a paid project.


cool though!

[matt]

That's the good part.  I am only welding it.  Labor only.  He is suppling everything else. 

He hopes to have under $1000 in it when he is done and off the shelf are 2500 and up.

The car is a 68 pontiac that goes roughtly 8.40's in the 1/4 on alcohol.  He runs a pontiac motor so parts are expensive comparied to a Chevy.  I believe it is an all aluminum motor.  $$$$$$

[M4wdFab]

got it.  make sense out of chevy land

[rejeep]

Might need your skills if I drill one too many holes in the cj6

[matt]

Might need your skills if I drill one too many holes in the cj6

Let's just hope you don't do that

[cracker]

wow.. spend over $1000, just to shed 17lbs from a car..

[gif]

wow.. spend over $1000, just to shed 17lbs from a car..

for $500 I could have cut something 20lbs off the car   

[M]

wow.. spend over $1000, just to shed 17lbs from a car..

Just wait until you check out elite road racing bicycles.  People spend thousands and thousands to save mere grams!!!!!

[Wingman]

Diet is way cheaper.  Save money on food too.

[matt]

Some more progress

Welding in the bungs for the injectors

They are all off to guy to be pressure tested before the fun begins of welding them onto the flanges.

[matt]

finially finished

Some more pics

Didn't come out too bad for a backyard welder.