I am pretty new to welding and will be using a Miller 140 Auto-Set (MIG) with the spool gun for aluminum. I've only used it for steel but I'm pretty sure Mrs. Santa will be putting a spool gun under the tree.

This is a no-boost application. Shape and size will be figured out modeling with cardboard, wood, whatever, but I wouldn't even know where to start figuring out exactly what material I need to use, so:

What thickness of aluminum should I use? (I'll need to see if my welder can handle this)
Is there a general rule to calculating the thickness I shoud use? i.e. I would guess a section that is 12x6 would need to be thicker than 4x4 section?
What alloy should I use?
How thick should the TB mount flange be?

I am not that concerned with overall manifold design as I'm really just making modifications to go from a carb mount to a TB mount in such a way to clear a low hood. If I go elbow style I will use a readily available "carb spacer" as the mounting flange to the manifold.

It's for my 85 corvette track car that has had the long runner TPI removed in favor of a single plane style manifold. I also have a 99 Integra that I daily and autox which is why I'm on HT. I was quite happy to find this section!!

 

bump for not wanting to spend hundreds on an intake!

my intake is alum. and prob 1/12 inch thick..don't know for sure, I just spend the hundreds for the name.