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  1. #1
    ctriverguy's Avatar
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    splitting an intake manifold?

    found my boost leak .. right along the main seam on the outside portion of the intake..

    I want to split it and take a crack at making something like the one offered from seadoo centre.

    I started with a propane torch and found it heated the plastic a little too quick and uneven...


    Anyone have a few pointers to doing this..

    Im also wondering if i should just take a dremmel to the lower half?

    Any thoughts/comments appreciated, thanks guys


  2. #2
    rxpdz's Avatar
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    This is how I ended up cutting my apart, I acctually cut it along the seam, place where it was put together.

    I can put in some pic's of my intake build if you want.

  3. #3
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    I split one apart, made my own version...I got 3 more manifolds I'll be modifying and building

    http://greenhulk.net/forums/showthread.php?t=93690

  4. #4
    ctriverguy's Avatar
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    thanks danny, didnt see that in a search..

    gonna use this

    http://www.rossmachineracing.com/halfround.html

    they have a pre cut end cap that I'll tap for accessories

    but still looking for a throttle body adaptor

    when splitting did you just beat the shit of the lower portion?

    I guess im just afraid messing up the runners..

  5. #5
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    Thats who I used, but its TOO TALL in stock form, you need to trim the D-round as its 4" tall, which will give you WAY to much volume before the runners...

    I'll post some more detail pics from mine, as I took almost an inch out of it to get the plenum volume the same as the plastic unit...

    Also, you don't want the front to be flat, you want an angle to help flow...

    I used a few flat heads and a simple torch to heat it up...You'll see your trim lines, get it soft and you can split it by hand once you get a hole started...

  6. #6
    GOT BOOST? Dockside's Avatar
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    +1 on more details and maybe a pic of it installed if you have one?....

    It's cold here and i need a project wouldnt mind maybe trying this. I could do all the fab work, I wonder how much toget someone to weld it all up would be

  7. #7
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    Here are some pics from when I made mine. The main bod is 12" long, and I reduced the heigth by 3/4 to make the volume of the plenum roughly the same as the OEM (minus the runner's volume...

    I used 1/4-20 aluminum threads and tapped the plenum plate, screwed them in and then welded then in...ground them smooth inside...

    My only mistake was indexing the TB plate, I was 45 degrees off...MAINLY because I mocked it up inside of Hallpass's GPRXP, not mine (was covered up) ...I fixed that with an adapter plate

    Just a time consuming project, cutting material and fab time...I had a friend tack it together, then I took it to a local welder and had him TIG it all around...

    Otherwise it bolts right on, power delivery is smooth and very responsive.
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  8. #8
    GOT BOOST? Dockside's Avatar
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    Would i benefit from this with an S3 or X charger set-up, Wondering what kind of gain to be had doing this? Also what did you use to bond the pieces together.

  9. #9
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    Quote Originally Posted by sportsterme View Post
    Would i benefit from this with an S3 or X charger set-up, Wondering what kind of gain to be had doing this? Also what did you use to bond the pieces together.
    You will gian a little more PSI at the manifold, since there is no flex/expansion from the lower half of the manifold...IMO both S3 and X will net the same when setup right...

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