Paul wrote:

Here is a how to make a template for your intake manifold
flange. Once you have this made in 1/8 inch  Lexan you can scribe a few
orthogonal lines on it and either send it to me or make  a drawing for me.

Much thanks to Brian Trubee for coming up with this method.

The first picture is of a transfer punch. You will use this tool
to mark the center of the holes. Not absolutely necessary as you could
clamp the Lexan to the intake manifold and match drill the holes
with a "S" letter drill.

Third picture. Template is bolted to intake manifold with 8 mm bolts and
I am routing out the intake ports with a flush laminate trim router bit.
The ever present Mikey is in the background.

Fourth picture, scribing the outline of the manifold on the Lexan.

Fifth picture, template more or less done.
Final finishing on the outline  can be done with a jig saw and
a small 1/2 - 3/4 inch drum sander chucked in  a drill press.

Should take about an hour and a half with the right tools.

Sixth picture, Klaus's girl friend across the taxi way distraction :-)

Paul Lamar

Bulent Aliev wrote:

I just would like to remaind you that the factory flanges do not match the
intake ports perfectly. The best thing to do is after you drill the mounting
holes, do the routing with the template attached to the engine.

Good plan Bulent.

Paul Lamar
 
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