Forums/Z31P/z31-performance-upgrade-forums engine-mechanical-aa/Gutting intake plenum without a milling machine
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BLITZERKING1: (2016-12-12 22:40:10)
So I ordered a used intake plenum with the intention of gutting it and getting an asco top plate welded on. I just wanted some opinions on what kind of tools people have used to gut these themselves. I know I could take it to a shop to get milled but I'm on a budget and I'd like to avoid that if I could. I have an angle grinder with a cutting wheel that I was hoping I could do most of the work with. Any suggestions or ideas?
nismo kid: (2016-12-12 23:01:24)
An angle grinder with cut off wheel & flap disc kinda works. Do not waste your time using a stone grinder attachment. You'll still need to use a dremel with flexible attachment to finish it off. Even then it's a lot of work. Many of us have tried this route. It's really not that expensive to have a machinist gut it. Been quoted .5-1hr to have a machinist knock out. The expensive part is the welding of the plate & deleting everything. I've gone both routes. The machinist route is the most efficient & cost effective way. I've been there done that & got the T-shirt.
BLITZERKING1: (2016-12-12 23:05:35)
An angle grinder with cut off wheel & flap disc kinda works. Do not waste your time using a stone grinder attachment. You'll still need to use a dremel with flexible attachment to finish it off. Even then it's a lot of work. Many of us have tried this route. It's really not that expensive to have a machinist gut it. Been quoted .5-1hr to have a machinist knock out. The expensive part is the welding of the plate & deleting everything. I've gone both routes. The machinist route is the most efficient & cost effective way. I've been there done that & got the T-shirt.
Thanks for all the info. I think I'll use my angle grinder to do a good chunk of the work and the have the rest milled. I think there is a shop that is somewhat local that can do it. Thanks again
mtherkamp: (2016-12-14 13:11:31)
I used a recip saw and metal cutting blade. Much faster than a grinder. There are pics in my build thread of the process.
Timbo_021: (2017-01-03 10:50:02)
I hacked out most of mine with a grinder and finished it off with a mill at work. Although I didn't pay for it and did it myself, it doesn't take long at all when its at the stage.
Timbo_021: (2017-01-03 10:51:35)
Oh, and I did use a die grinder after milling to get a kind of bell mouth around the ports. Counter sunk holes for bolts, yada yada yada.. Seems to work well.
frostvectron: (2017-01-04 01:34:40)
Random thought: would aluminum brazing work to seal a new top on? Much easier than welding, great for sealing, but not as strong as welding. People typically use it for boat repairs.
Timbo_021: (2017-01-04 07:00:09)
Why not weld? Last thing you wanna see is danger to manifold light flashing on the dash.. [archived image: tongue.png]
BLITZERKING1: (2017-01-04 09:43:57)
Apparently people have blown the welds on intake manifolds running 20+ psi of boost. I guess the fast and furious wasn't lying lol