When using round runners, is there an easy way to form the runner to an oval shape to match up to the flange?

Could I have a piece of metal cut to make a "die" to use in a vice to squish the end of the runner? Like a piece of steel...and maybe heat up the aluminum runner? We are talking about 1.5mm thick aluminum.

 

hmmm, interesting question...

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about a year ago i was on fab-forum.com (i think that was the site) anyways.... a guy made something like you describe but used two bolts to squeeze the pipe into shape, this was for a dsm intake manifold.

 

we put them in a bench vice and it worked out pretty well. (im talkin about weld el's for exh manifolds)

i would imagine a 2 part die, and using a hydrolic/air powered shop press would be a much more consistant and desirable method.

 

To ovalize a 1.63" primary into an oval port I have made up a die/dolly. This was a must for certain primaries as they are cut on an angle or bend, which makes things a little more complicated. I basically formed the die out of solid steel, in the shape of the port, and built it with a 30* or so taper, welded a short handle and flat end. Then simply shape in vise with hammer, wedging die into primary tube to expand or swage pipe. There are better more efficient ways to go about this, but at the time I needed a quick answer with what the materials laying around the shop.

 

a big bench vice usually works pretty well

 

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thats what i do too

 

cut a flange in half, and then use it as a die in a vise. might be costly though to chop up a perfectly good flange, haha

 

Take a metal rod that diameter, ovalize it (grind top & bottom), then insert into pipe to be shaped, and stick in a vice. I've had issues where one side gets bent more than the other (when crushing w/o die), this way it will stay pretty much even, and top/bottom are nice and flat.

 

not a bad idea, but unless I'm too tired to think striaght, wouldn't you also need the "male" part ( Die) to form the pipe?