So im trying to figure out the best way to do this. It would be a lot easier if i had 2 runners per port, but i only have 2 runners leading up to the flange so one runner per port on the divided flange. This is with 1.5" sch40 tubing and its for a subaru application.

Im thinking of getting a new flange machined just for this application which will have slightly smaller ports to match up to the formed/ovalized sch40 piping. Im trying to eliminate as much gaps between the tubing and the flange as possible to avoid filling gaps and get a good fitment.

How would you guys with more experience go about doing this?

 

Eh, don't worry about gap so much. Get it close, use a hammer and chisel to get it closer, and know how to use your filler rod, and you'll be fine.

 

ya, im fine with using the filler rod to fill. But I just like everything to fit align "perfecty". Was wondering if there was some kind of trick i hadn't thought of to try and shape/form the tubing to where they both sat nicely on the ports.

 

I designed and prototyped this one for full race. Fit up is perfect.

I can't legally say how I did it exactly but with a 5lb sledge and a small anvil pretty much anything is possible, our gaps were smaller than 1/16 to the flange before welding when fit properly.

 

Ya, i ended up just muscling it to shape today and got it to fit nicely. I guess i was just looking for a quick and easy approach if there was one. But it went, thanks for the tips on taking the forcing into shape approach.