Subject: Manifold assembly
From: ACRE
Date: 9/15/2003, 9:35 PM

This is kind of tricky.
I was in a rock and hard spot with this design as I had to
suck the runners in so I had bolt clearance on the top
outer manifold  bolts. This meant it was kind of tough to weld the
tubes to the manifold completely around the base of the
tubes to prevent leaks. I don't know how Bill Schertz
accomplished this as it is rather hard to get a tig welding
torch in there to do the job. Perhaps somebody skilled
with a gas torch could do it. Has anybody else completed their
manifold? I guess you could use Tracy's favorite material
JB Weld to seal any leaks. Much like is done with rad cores
now a days.

Plan B:
I figured out how to do it with a small spacer pieces 
pre welded between the tubes. The idea was then to weld
the two tube assemblies to the lower half of the manifold.

The next problem was how to make these spacers with common 
hand tools. Bill Mensinger at Sheet Craft came up with the 
solution. Use a fly cutter in a drill press to cut three 
holes with the same OD as the tubes in a piece of 3/16 
thick 6061 T6 plate and then cut away what you don't need.
Step by step illustrated in this 3D.

BTW when you cut and fit the tubes makes sure the tops of the
tubes are in a line as the injector runners are also in a similar
line up to insure all four injectors fit the fuel rail.

Paul Lamar
 
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