Zerb's 90Q 07K...Intake manifold fabrication

[PRY4SNO]

Looks real good in there. Keep up the good work!

[chaloux]

Yeah this is awesome. Can't wait till you're hunting liter bikes again lol

[Zerb]

so, did some work on the aluminum thermostat housing today, almost finished. just a few more tweaks to the angle of the pipe that goes to the water pump and we will be set.








Started some work on the aluminum piece that comes off the back of the head as well and goes to the upper rad inlet, that will also have a -8an port for a thermostat bypass line, as well as a threaded bung for coolant temp sensor.

[highlander69]

Another great build !!!!!

Looking forward to updates.

Cheers,

Craig.

[Zerb]

Got some time spent with my new tig welder today. Not the ugliest welds ever, not the prettiest. Manifolds coming together. Got some of the coolant flange off the head done as well.






Sent from my SAMSUNG-SM-N900A using Tapatalk

[Zerb]

So. Little update randomness.

Bought a nifty mitre saw. Cuts any material, and does it quite well I might add.


Made a different, stronger, intercooler mount. The more I redo, the more I can practice tig welding. So it's a win win.



Ordered a set of universal fiberglass fender flares from eBay. They will certainly fit the bill. Just not sure if I want to chop them off at the bumper lines, or cut them at the bumper lines and rivet the lower sections onto the bumpers.






Here we have a catch can design that I had bouncing around in my head for a bit and decided to design it on the computer and have my buddy jet the parts out for me. It'll take better shape in the coming days, but you'll get the jist. The rear piece will curve to the front of the can like the side plates are cut. Then 90 down. The AN fittings will be facing the front of the can, hoses will go directly over the large panel filter. And done.



Where will It be venting from to that glorious can? Well from this valve cover I also designed and had jetted by my buddy.





Fittings were placed there because as I've read and seen in my research of these 07k motors there are two ports that run down the head there and into the crank area of the block for venting purposes, so I wanted the most direct route for those passageways to breath.

designed this as well and had it jetted. still haven't made a final decision on where to put it.


Some of my aluminum welding on the new upper rad support bar I made.




And that's that. Lots more to come. Tons of nifty ideas in my noggin for this one.

posted from a computer in my pants

[scubagli]

Nice, i say cut at bumper.


Old and grumpy.

[Zerb]

Got some more of the catch can welded up today.






Should have the baffle plate tacked in there tomorrow then I can weld the filter plate in there and finish off the top vertical section you see there with the AN fittings.

posted from a computer in my pants

[audifreakjim]

You are getting better and better at welding! This is exactly the type of stuff I want to start playing with, just need to pull the trigger on that TIG..

Keep at it, can't wait to see it run.

[Zerb]

I would recommend this Eastwood tig 200 after using it for a bit and having my buddy who does this as a profession use it and say it's quite nice for the price. Can't go wrong. Only shitty part was the pedal setup they have

posted from a computer in my pants

[Afterthought]

Great fab work, and I really like the old school 20v turbo letters! nice looking intake too

[my2000apb]

how are you going to affix the "20v turbo" to the manifold?

[Zerb]

we welded little blind rivets on the underside of it, i will drill into whatever its getting mounted to and affix it that way

[Zerb]

Well. Chalk this one up as the first aluminum piece I have fully successfully tig welded myself. 98 percent done. Need to put some -10 bungs on there and some mounting tabs and we are done.



Now I can get rid of the holes in my firewall.



posted from a computer in my pants

[themagellan]

What a wonderful setup that is, love everything in here

[Colin2750]

Hood clear those AN lines?

[Zerb]

Hood clear those AN lines?

It's close. But yes.

posted from a computer in my pants

[Zerb]

Started a little intake manifold fabrication this evening. I fucked myself pretty good when I welded that plenum up, it was one of the first things I tig welded when I was learning and needless to say I didn't clamp it down anywhere and it warped, so these runners were white the bitch to get to fit properly. I had to give up a little of the perfect fit I was after just to save my sanity. I can weld it and grind it all that I need after all.




posted from a computer in my pants

[Hank]

Looks good. You are probably going to hate life at some point with the catch can location. The rear of the engine cover is the new tight spot in 07k install. Any cam adjustements, head pull, etc, that catch can will need to be removed.

Looks great dude.

Hank

[Zerb]

catch can will be held to the firewall with 2 bolts once i weld tabs onto it and press some nut serts into the firewall. so it will be easily removable, hopefully. i thought about sticking it up in the raintray and having the can in the cabin but the top of the can protrude out of the raintray and also have a square cutout for the filter to vent, but i feel as if that may stink up the cabin

[Zerb]

Plugging away






posted from a computer in my pants

[Zerb]

Bang bang






posted from a computer in my pants

[ChrisAudi80]

I love watching intake manifold fabbing. Don't know if you mentioned it earlier, but what TB will you use? The funnel to the plenum looks large. 4"?
Injector bosses next?

[Zerb]

Injector bosses and the 2 triangle pieces I need to finish up the plenum. 75-80mm throttle body. Then it's on to intercooler end tanks and the exhaust manifold

posted from a computer in my pants

[my2000apb]

any oilpan progress?