Project started with a new Holley EFI Tall Deck Dominator Flange intake. Customer needed a manifold to fit under the hood of blown 540 C4 Corvette and wanted to modify this manifold to achieve his goal.
First step was to cut off the top of the plenum with a bandsaw. This was done to save the flange. It may come in handy one day.
Next, the time consuming milling task of getting rid of the existing plenum area was done on a Bridgeport Mill.
This is the intake after the plenum and water neck were removed. The fuel rail post were left on since they would be needed to mount the customers fuel rails.
Old water passages were modified by blocking the path and adding bungs to redirect the water to clear the new plenum.
Close-up of the blocking plate and bung that were added. The bung uses an o-ring to seal a -10 AN fitting.
The milling operation left sharp edges on the ports which would make air entry inconsistant between cylinders.
Runners were ported and the entry radiused for smoother air flow.
The pieces were made using .125 thick T6061 aluminum from templates using thick drawing paper.
The Arizona Speed and Marine 1300 cfm Throttle body was used as a template to make the mounting plate.
The semi-completed manifold.
The completed manifold shown next to customer supplied profile model.
