For a plenum design I want to have an underlying skeleton that I can attach the runners and the endcaps/flanges to, and then wrap an aluminum skin over it.

Like so



The skeleton will be 6061 1/4" aluminum. What thickness aluminum sheet metal can I use that will bend over easily, but still be weldable. I'm guessing that keeping it 6061 would be the best bet?

Heres some of the thickness mcmaster-car offers
.032" | .033" | .04" | .048" | .05" | .055" | .06" | .062" | 1/16"


Modified by Westrock2000 at 12:57 AM 8/2/2007

 

You can still use 6061, but not T6. You will want something that has not been hardened so that you can form it without destroying the metal.

 

I'd recommend 3003 or 5052 if you're going to bend it. Is this manifold going to be in a turbocharged application? You could probably get by with .065 in an n/a app, but definitely not in a turbo app.

 

take a look at http://www.rossmachineracing.com

 

dude just get a tube of what diameter u need (i use 1/8" wall 6061 for my stuff) and cut it in half............... thats waht i do for my manifolds.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by hootiehoo &raquo;</TD></TR><TR><TD CLASS="quote">take a look at http://www.rossmachineracing.com</TD></TR></TABLE>

I'm actually using their halfround for the skeleton. However the ID is too small to fit the velocity stacks comfortably (87mm bellmouth & 89mm ID halfround). But by wrapping a skin around, I gain an additional 1/2" which gives me breathing room around the stacks.

This particular one would be for NA, potential future customers may look into FI applications though.

Tony do you know any good welders in the DFW area?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Westrock2000 &raquo;</TD></TR><TR><TD CLASS="quote">

I'm actually using their halfround for the skeleton. However the ID is too small to fit the velocity stacks comfortably (87mm bellmouth & 89mm ID halfround). But by wrapping a skin around, I gain an additional 1/2" which gives me breathing room around the stacks.

This particular one would be for NA, potential future customers may look into FI applications though.

Tony do you know any good welders in the DFW area?</TD></TR></TABLE>

I'm guessing that he's going to reccomend himself

and I've also read that a TB in that location isnt the greatest for airflow distribution, which might make a pretty big difference in NA performance.

I think you'd want to move the TB up above the stacks more, and "away" from the rest of the manifold.

 

Tony is as good of a welder as you will find...

There aren't a ton of really good welders in this area, well at least not like Austin or Houston.

 

I can stick metal together ok on a good day

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">I can stick metal together ok on a good day </TD></TR></TABLE>

OK, I wasn't sure or not. I had a close friend whom you tuned his AEM EMS, so I knew that aspect, but I wasn't sure about custom fab stuff.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Westrock2000 &raquo;</TD></TR><TR><TD CLASS="quote">

OK, I wasn't sure or not. I had a close friend whom you tuned his AEM EMS, so I knew that aspect, but I wasn't sure about custom fab stuff.</TD></TR></TABLE>

yeah, tony1 posts some pics of his work in this section, and its all top notch

whats your take on my design comment? not enough space, evidence to prove otherwise, or what?