So after a few sleepless nights of pondering intake runners there isnt really any good way to transition from round runner tubing to a rather extreme rectangular port. The obvious solution is to make rectangular port runners as seen on many of the intake manifold from Hogans Racing and others. Is there off the shelf aluminum rectangular tubing that has nice radiused corners or am I going to have to make a wooden buck or design a die for a press to form these bad boys. Im leaning toward making a die for consistency and although the initial time spent will be alot, it seems like it would save time in the long run.

Anyone have some input?

 

Flat piece of sheet, bent around a wooden die and welded up on the seam.

 

i'm working on a design for a die that would be used in an arbor press to make oval shaped runners from round pipe. you can get some rectangular aluminum tube with radii in the corners but i'm not sure if it would match what you need.

 

Where have you seen rectangle tubing w/ radii on the corners. Everything Ive seen has been sharp angles?

 

Maybe get some thicker wall stuff and stretch it really slowly or heat it a bit....

Actually, why is this even a problem? get some square tube, hammer a cone into it until it's round....if you gotta go wide, so what, the funneling is good for it. Square turns round a lot easier than round turns square.

 

gonna end up making a die to press form em....seems the most accurate way to duplicate them over and over.

 

Really the easiest way, if you have a good press, is to make a tapered cylinder. The taper should go from a size that inscribes the square to a size that is equal to the inner perimeter of the square. Grease it, press it in. There should then be a good transition from square to round that is repeatable.