I made an intake manifold flange for a 6 port using a router and a carbide
bit with a roller guide. I clamped the plate to the intake manifold, drilled
the holes for the mounting bolts, bolted the plate to the flange. I  then
scribed and cut the rough shape of the outside of the flange. I also cut
small holes for where the ports were to accomodate the router bit. Then,
moving around the clamping bolts. I routed off the excess material until the
flange was complete. You just have to go a little slow to avoid grabbing, but
a carbide bit will cut aluminum just fine. It works pretty well if you are
doing a small number of flanges.
Brian Trubee
Redmond, Wa

 
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