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09-18-2005 06:01 PM New shop goes in 1
We moved to a new house and I built a clone of the shop I just left. 1700 sqft, paint booth, wood shop 3 car bays and an in-ground hoist. It was great but there were a few things I wanted to do differently here. First, my new one will be insulated and dry walled. The bare frame in the old one was just too dark and dirty. With finished walls it will be much easier to keep clean.

First photo shows the shop in sticks. Has to be built to code and in Kalifornia that means earthquake so there are a lot of shear walls.

Second shows it ready for stucco.

Third shows the outside done. Note the forms for cement. I poured 1600 sq ft of cement around it. 19' in front of the doors so cars can get in and ALL around - no weeds to mess with. My last shop had 6' of dirt on three sides and I was constantly hacking weeds out.

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  [Entry #142]

07-17-2005 09:25 PM Casting a custom intake manifold 7
Look what I found! While packing our stuff to move I ran across these drawings I did in preparation for making the manifold.

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  [Entry #141]

06-28-2005 08:52 PM Casting a custom intake manifold 6
Here is the finished product on the engine. I polished it as you can see. When we got the engine running, it was a monster! The manifold really worked great and the engine torqued like a small V-8, cruised cool at 60 all day long and got 25 mpg.

You can see the flange and chamber I designed on the bottom to install a flat aluminum plate for preheating the manifold w/ hot water or exhaust gas but I never got around to installing that feature. It needs it, pretty cold blooded on startup.

(click photo to enlarge)
  [Entry #140]

06-28-2005 08:50 PM Casting a custom intake manifold 5
Photos 1 & 2 show the finished manifold. Forgive the photo quality, they were taken pre-digital and scanned into my computer. If you squint you eyes just right you can see the tow sides of the split plenum under the carb adapter. I bought the 4-bbl carb adapter from Clifford Performance and used it just like he does on his performance intake manifolds. Just had to drill and tap 4 holes. The intake on these engines are held on by lugs so no precision mounting holes were needed.

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  [Entry #139]

06-28-2005 08:23 PM Casting a custom intake manifold 4
Oner more custom piece was needed before I went to the foundry to have the manifold cast. Photo 1 & 2 show the split plane I made form fiberglass that cut the manifold into two pieces to facilitate the casting process. The wood pattern is set into this piece (photo 2) and a wood box is set on top of it and specially formulated sticky casting sand is pounded on top of that. This box of sand is removed and turned over with the wood pattern now half embedded in it. A second wood box is set over that and more sand is pounded into that box. The two boxes are separated and a cavity representing a negative of the outside of the manifold isl left. The sand cores that were made as per the previous installment are set into the cavity exactly as the plater ones were set on the board in previous pictures. The top sand box is placed on it and the result is a cavity exactly the form of the finished manifold. Aluminum is melted and poured into this void. When cooled, the sand is knocked off and out of the aluminum and I a manifold that needs a LOT of work to finish. There are various sprues and runners that are part of the casting process and need to be sawed off. Then the carb surface and intake surface are simply sanded flat on a big belt sander.

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  [Entry #138]

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