My intake manifold project - Ford Powerstroke Diesel Forum
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post #1 of 92 Old 04-28-2013, 12:39 PM Thread Starter
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My intake manifold project

Wasn't gonna bother taking pics as I know there are few of these threads floating around. But here we go, got this manifold from a member here. Have done most of the work with an angle grinder with a cutting wheel with help of saw zal, and dremel. Plan on welding it back together with my mig, gonna hook up pure argon and give it a shot, if it doesn't seem to start out well I'll quit and get someone to tig it for me.

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05 250. Lariet. 4x4.
arp studs w/oem gaskets & all updates
Warren 175cc/stock sticks
Egr delete
Zoodad
New oil cooler
Coolant filter w/ zerex ec-1(homemade)
4" turbo back, straight piped
SCT livewire (running TSD SPD)
KC Turbos 1.5
Blue spring upgrade
riff raff boots
Ccv reroute (dump to atmosphere)
Air Horn Kit
high idle
Pro comp "bullet hole style" 17" w/ 35" nitto trail grapplers
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post #2 of 92 Old 04-28-2013, 01:25 PM
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just picked up a spare to do the same... looks to me the biggest problem is at the bend under the alt bracket. was thinking I would split mine the same way. take a pic of that restriction if you would please. can you grind it ok the way it is split, are you going to counter sink cap screws?? thanks for posting!!!

Aaron 2005 f250 552/1040 45k miles
S&B. 4" mbrp, Arp's, Dual oil bypass. CCV fltr, Clnt fltr Mag trans pan 08 diff cover. 4.10's, 315's MotoMetal 951 & 5" lift.TGC trac bar, Bislstien Shocks & Dual stear stabilizer. B&W . Air Rides. Snows MPG Max. Edge Insight, fuel sens. DC Eng.185 alt. 58v ficm 6.4 Juger pump Fass sump
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post #3 of 92 Old 04-28-2013, 05:26 PM Thread Starter
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I'll get a pic of it tomorrow for ya. It is a little tricky with an angle grinder but I was able to get it. Just put on the grinding wheel and have at it. Not sure if I'll counter sink the bolts or not. Probably not just to save the extra work lol. Theres enough to it already. Once you get those runners cut out and start smoothing out the floor of the manifold you can see how much room is opened up inside this thing.

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05 250. Lariet. 4x4.
arp studs w/oem gaskets & all updates
Warren 175cc/stock sticks
Egr delete
Zoodad
New oil cooler
Coolant filter w/ zerex ec-1(homemade)
4" turbo back, straight piped
SCT livewire (running TSD SPD)
KC Turbos 1.5
Blue spring upgrade
riff raff boots
Ccv reroute (dump to atmosphere)
Air Horn Kit
high idle
Pro comp "bullet hole style" 17" w/ 35" nitto trail grapplers
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post #4 of 92 Old 04-28-2013, 05:34 PM
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started grinding on the main inlet and cut out inner egr crap. will split mine this week. thanks. how long of cap screw is needed to bolt to block and what is you plan for plugs?

Aaron 2005 f250 552/1040 45k miles
S&B. 4" mbrp, Arp's, Dual oil bypass. CCV fltr, Clnt fltr Mag trans pan 08 diff cover. 4.10's, 315's MotoMetal 951 & 5" lift.TGC trac bar, Bislstien Shocks & Dual stear stabilizer. B&W . Air Rides. Snows MPG Max. Edge Insight, fuel sens. DC Eng.185 alt. 58v ficm 6.4 Juger pump Fass sump
NO more mtw turbo
AJB Custom R.R.
AJB Custom y pipe
AJB P&P Intake
PHP Gryphon
Banks IC
BARDER Stg2
Warrens 175/30
P.I. T.C & input.
Flight Fab. Track bars
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post #5 of 92 Old 04-28-2013, 07:02 PM
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Looks good, I'm still debating weather or not I'm going to tackle my own. If you have a spool gun for your mig you shouldn't have a problem welding it back up.

Cameron
2006 F250 Lariat CCSB
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post #6 of 92 Old 04-28-2013, 07:29 PM
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Whether you MIG it or TIG it, make sure you rig up some way to pressure check it.

I have done six or seven of these manifolds now and this last one was the only one that I was able to get TIG'd together perfectly the first time and seal completely (took me twice as long though ). Of course it didn't have quite the extensive amount of welding that a couple of my other manifolds did either.

Just saying that it kind of defeats the purpose of doing the whole thing just to have to have it leak ever so slightly on you. Looks good though.

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post #7 of 92 Old 04-29-2013, 04:32 AM Thread Starter
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Quote:
Originally Posted by windrunner408 View Post
Whether you MIG it or TIG it, make sure you rig up some way to pressure check it.

I have done six or seven of these manifolds now and this last one was the only one that I was able to get TIG'd together perfectly the first time and seal completely (took me twice as long though ). Of course it didn't have quite the extensive amount of welding that a couple of my other manifolds did either.

Just saying that it kind of defeats the purpose of doing the whole thing just to have to have it leak ever so slightly on you. Looks good though.
Yea I've been thinking of this the whole time. I've got to get it checked just not sure how yet. What did you do?

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05 250. Lariet. 4x4.
arp studs w/oem gaskets & all updates
Warren 175cc/stock sticks
Egr delete
Zoodad
New oil cooler
Coolant filter w/ zerex ec-1(homemade)
4" turbo back, straight piped
SCT livewire (running TSD SPD)
KC Turbos 1.5
Blue spring upgrade
riff raff boots
Ccv reroute (dump to atmosphere)
Air Horn Kit
high idle
Pro comp "bullet hole style" 17" w/ 35" nitto trail grapplers
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post #8 of 92 Old 04-29-2013, 04:50 AM Thread Starter
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Quote:
Originally Posted by bondajb View Post
started grinding on the main inlet and cut out inner egr crap. will split mine this week. thanks. how long of cap screw is needed to bolt to block and what is you plan for plugs?
Not exactly sure on the length, I wrote it down but can't remember. I just measured how far one come out the bottom while the intake was still whole then put one in just the bottom half and did the math. Just gonna use a threaded plug for the top, kinda like what a block drain plug looks like.

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05 250. Lariet. 4x4.
arp studs w/oem gaskets & all updates
Warren 175cc/stock sticks
Egr delete
Zoodad
New oil cooler
Coolant filter w/ zerex ec-1(homemade)
4" turbo back, straight piped
SCT livewire (running TSD SPD)
KC Turbos 1.5
Blue spring upgrade
riff raff boots
Ccv reroute (dump to atmosphere)
Air Horn Kit
high idle
Pro comp "bullet hole style" 17" w/ 35" nitto trail grapplers
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post #9 of 92 Old 04-30-2013, 02:38 AM
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Is there a big power gain doing this mod?
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post #10 of 92 Old 04-30-2013, 02:44 AM Thread Starter
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Just by looking at the sheer volume increase inside the manifold when doing this I would imagine there would be, at least I hope so. Of course the heads now become the bottle neck in the system

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05 250. Lariet. 4x4.
arp studs w/oem gaskets & all updates
Warren 175cc/stock sticks
Egr delete
Zoodad
New oil cooler
Coolant filter w/ zerex ec-1(homemade)
4" turbo back, straight piped
SCT livewire (running TSD SPD)
KC Turbos 1.5
Blue spring upgrade
riff raff boots
Ccv reroute (dump to atmosphere)
Air Horn Kit
high idle
Pro comp "bullet hole style" 17" w/ 35" nitto trail grapplers
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