I'm going to be making an intake manifold flange at my place of employment on the side.
I will be using the available equipment to establish factory locations for injector bungs. The ports will be made to seat the extruded runner tubing I have. This will be an H series application. My question is if I were to convince my employer to allow me to make more than one, or even possibly B series or K series flanges are there people out there interested? I would think I could make them for around 200$ give or take.

 

I think a few people already make these for the B and K Series, but the H-series might have some demand..

 

who makes them out of curiosity?

 

There are some guys who are making them tad cheaper then $200. Yet, you need to talk to the administrator about sponsors, if you EVEN think about selling on this board. Before you get ban. GL.

 

To high of a price. The industrial market to that of a automotive part is a huge difference in price. As you would sell a CNC'd part to an industrial company for 300 you would be lucky to see a similar part for the auto industry for more then 75. Unless you do huge quantity of one thing or make one off parts for the auto industry you will have a hard time to survive. For example we got prints in from Moroso to do some work for them but they dont want to pay for anything and all they do is shop around for the cheapest rate possible.

 

 

I hace a CNC fixture that does b16/b18c5 intake manifold flanges. Hit me up I'm looking to sell it

 

I know its been a long time but here are some pics after ops 1 and 2 are done. We created a solidworks file of what I wanted and generated tool paths from that.

 

that looks like an awful lot of machining for a flange.

 

ya it is a lot of cycle time. Im only making two of these manifolds one for my car and one for a good friends. Im confident we designed something better than I coulda bought.

 

i've already made my own cnc program for doing exhaust flanges im gonna tackle intake next.
any tips on doing the injector bosses? thats the part im most concerned with

 

Well I can only tell you how I went about doing the design and programming I guess. We used the Zeiss CMM, a cut intake manifold, and a cylinder head to create the solidworks file. Then imported that solid file into mastercam, chose tooling and generated tool paths. I used a 7/8 convex cutter to surface the ports so the angles and tapers were what we found in the cylinder head just extended to gradually get to the size of the I.D. of the oval extruded runner tubing I have.

To program and design this from scratch the old fashioned way would be a nightmare and I wouldnt even know where to begin. The injector bosses were roughed and finished with a 3fl. 390 sandvik indexable cutter (op 2). On op1 they were roughed with the same sandvik and finished with a .015 R 3/8 4fl. endmill.

 

3rd operation cutting injector bungs from mani side is done..... now I have to figure out how to determine a workoffset for the last operation of cutting the port side of injector features. FML

 

that sir is absolutely gorgeous, man i miss machining..

 

That is a hell of a lot more machining than I would be willing to do on a knee mill, especially without an enclosure. Looking good.

 

The quality of work looks good, but why not transition to a round ID since you come out that far? Round flows better, and is easier to source runners for. Just curious.
I mean if you are going to machine everything, then who cares.
They look sweet.

 

It's going into a mostly oval shaped port.... there are pro's and con't with it and I see your point.

 

Are you able to provide a source for the extrusions matched to your flange if someone buys one of your extras? I want to make one mani for myself and I like your flange big time.

 

LOL operations 1 and 2 were done at my employers shop..... 3 axis CNC, tool changer, hence the surfaced features port to runner transition and mani side of injector bung. Im doing the injector bung features at my dads (2 axis cnc kneemill).

 

I can get the oval extruded runner tubing I need.The port on the head is oval so I opted to use the oval tubing.

 

I made two one for me and one for a friend. There wasnt much interest when I originally posted. I can get the oval extruded runner tubing. PM me if you wanna figure something out.

 

**** as long as you can use the machine again, and have the block of aluminum, i hope u have the tool path saved. You can make them on request shouldnt take more than a couple of hours altogether.

good **** man.

 

I lucked out with my empoyer. I didnt know it when I was hired but the vice president(co-owner)is big into drag racing and he is pretty cool about allowing me to use the equipment and tooling on my own time.
I have all the necessary data to make more but Im not even thinking about selling anything until I have a mani done and have proven hp #s!!!!!! Im sure it will work great but we all know the dyno doesnt lie lol..

 

yeah man thats cool, i took machining classes at a community college when i was junior and senior in highschool. Its hella awesome to make ur own ****. Me and my buddy made so much stuff for his quad, out of the scrap pile. hell we even made some sweet *** rear wheel spacers out of a abs plastic, and they were pretty strong. until u jump on them and crack them.

I used to draw all our **** in mastercam though or have a kid do it in auto cad, and i would transfer it over to mastercam, and tool path it out and ****. Its hella fun IMO, and we had alot of cool machines, wish i would have learned more, and still had access to that shop.

 

Your machining work is top-notch, but I don't understand how this is better than a flat flange design. Sure would be a lot cheaper to make and sell these if you simplified the design. Especially since you're trying to make them to be generic-fit for anyone. It's hard to compete price-wise with a waterjet cut piece of flat stock.

If I had the machining and design access that you have, I think I would've just made the flange and runners all from one piece of aluminum. Then you could've made the runners any shape and length you desire. Now you're stuck designing around existing runners, which are usually just straight extrusion.
Good luck with your project. Looks great!