Paul,

Got the headers back from the welder and they look pretty good.

The intake hardware had issues

He did not weld the injector holder to the 2" tube because the sample
weld that he ran just melted.

He said he needed a water cooled tig torch

The point where the injector holder contacts the tube at an acute angle
does not permit him adequate access

Should this piec use JB weld for sealing and tack welds to hold it
secure?

Was wondering what your experience was.

Thanks for any help

Joe Berki
Limo EZ

I have a couple more if you can find a better welder :)
Aluminum is not easy to weld.

You can glue them on with epoxy if you treat the aluminum
first.

Paul Lamar

Donnknow if a water cooled tig torch is the answer. The water cools the
torch, not the weld. Aluminum is difficult to weld because it tends to
melt away from you if you don't have the knowledge and experience to
weld it. It seems as if your welder was welding the aluminum as if it
were steel.

Get a different welder or perish the thought-- have a professional do
it. In my intake manifold, I welded what I could, but will use JB in the
acute angles and where I couldn't get my torch.

Rich

I gave the welder a sample of the tube that I wanted the injector holder
welded to.

I believe if i went with a thinner wall it would be a non-issue.

What wall thickness would you recommend for the injector holder tubes?

Joe

Greetings, Joe,

I used 16G runners to which I welded the injector bosses. I used 16
because I was able to get mandrill bends from which I made my manifold
(modified extensively from the existing Renesis)

Welding Aluminum, as I mentioned is quite tricky, and like flying
requires training and practice--(as noticed by the difference between my
first welds on my induction system, and the last -- in this current
series after not having done it for a year or so). Your welder should be
able to tell you which gauge metal he is comfortable welding (If any).
The thickness of the material, within limits should have no effect on
the weld or its possibility, dependent, of course, on the welder and
the type of equipment used. Something in the back of my mind says that
the Lincoln people were welding aluminum foil with their square wave
machine at OSH one year.

Aluminum can be welded with gas (acetylene and O2) with a Henrob torch.
When my son was in 7th grade, his teacher was teaching the concepts of
welding. He stated that Aluminum couldn't be welded with Gas. Whereupon,
taking the challenge, I, using the Henrob, welded two soda cans together
(at the bases-- a little thicker) and left the filler rod connected
--Not a lot of brownie points for my poor son.

Please understand, I am not a professional welder. Professionally, I
deal with headaches. Anything I might say on this list is a matter of my
understanding and personal experience.

I have attached a picture (sorry for the angle) and possibly size. (I
will try to get better pix later if there is interest) which shows the
welds and the induction system, some of the cooling system and exhaust,
as it matures.

Rich

Looks good Rich. I like the pocket in the Tracy PSRU spacer :)
I would love to see some more pictures. Bigger! :)

Paul Lamar


Thanks and sorry for the mungy picture. I will be at the airport this
weekend (if my pleading and begging has any effect ;-) ) and will get
better pictures which actually show something and have better
resolution. These were from my droid, e-mailed and cropped--- not good.

The pocket, to which you refer, will be filled with the appropriate
stuff. At this point I am installing the engine, its cooling, tubing,
piping, etc so that when ready, I will take the engine out, rebuild it
(even though it supposedly has only 14K on it) and reinstall it with the
appropriate stuff. Can't do much glassing, with our frigid temps, even
though the hanger is heated, keeping it warm for overnight cure is
rather dear.

I hope to have the engine installation finished by mid to late spring.

Rich