modifing intake manifold
Thread Starter
Joined: Nov 2008
Posts: 1,347
Likes: 1
From: Pittsburgh, PA
modifing intake manifold
Guys since my car is down for the winter I would like to clean up my intake manifold by getting it powder coated. I was wondering if you could mill off some of the casting marks and unused bolt holes (what held the fuel rail cover)? I would also like to mill off the not need egr port and plug the hole as the 06+ models didn't have that. Is this do able? Can people post pics of there intake manifolds.
Registered User
Joined: Jul 2010
Posts: 718
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I actually started making my own manifold using the the stock runners....I got a little trigger happy when it came to the EGR. Since i've got AEM and will no longer need it i completely grinded that entire part away...i'll post a pic tomorrow.
Joined: Oct 2000
Posts: 9,033
Likes: 21
From: South of the pier, Huntington Beach, CA
My current manifold is over 3-1/2 lbs lighter from removing material.
https://www.s2ki.com/s2000/gallery/i...1-dsc01316jpg/
I removed in total the smog pump flange and some bosses.
There is a large amount of aluminum that can be removed from that area.
https://www.s2ki.com/s2000/gallery/i...2-dsc01315jpg/
The braces are modified and removed.
The coolant flow parts were removed from the front of the manifold.
I only burp the coolant at the firewall. Works great.
https://www.s2ki.com/s2000/gallery/i...7-dsc00056jpg/
In this bottom view, all of the casting excess was removed from the runners.
Now it it easy to remove and replace the manifold. No blood loss from cuts.
Fingers fit between the runners to install the bolts, no long extensions necessary.
https://www.s2ki.com/s2000/gallery/i...1-dsc01316jpg/
I removed in total the smog pump flange and some bosses.
There is a large amount of aluminum that can be removed from that area.
https://www.s2ki.com/s2000/gallery/i...2-dsc01315jpg/
The braces are modified and removed.
The coolant flow parts were removed from the front of the manifold.
I only burp the coolant at the firewall. Works great.
https://www.s2ki.com/s2000/gallery/i...7-dsc00056jpg/
In this bottom view, all of the casting excess was removed from the runners.
Now it it easy to remove and replace the manifold. No blood loss from cuts.
Fingers fit between the runners to install the bolts, no long extensions necessary.
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Registered User
Joined: Mar 2009
Posts: 246
Likes: 0
From: Mill Creek WA
I started cleaning mine up last week, friend used a mill to knock off the stuff on the top, and I welded the holes shut. After cleaning it back off I welded a couple little holes back up and hes gonna knock it down final.
One more pass after this, then gonna cut off the egr stuff and weld a few other holes shut.
One more pass after this, then gonna cut off the egr stuff and weld a few other holes shut.
Joined: Jun 2010
Posts: 406
Likes: 0
From: Adkins/east side San Antonio
My current manifold is over 3-1/2 lbs lighter from removing material.
https://www.s2ki.com/s2000/gallery/i...1-dsc01316jpg/
I removed in total the smog pump flange and some bosses.
There is a large amount of aluminum that can be removed from that area.
https://www.s2ki.com/s2000/gallery/i...2-dsc01315jpg/
The braces are modified and removed.
The coolant flow parts were removed from the front of the manifold.
I only burp the coolant at the firewall. Works great.
https://www.s2ki.com/s2000/gallery/i...7-dsc00056jpg/
In this bottom view, all of the casting excess was removed from the runners.
Now it it easy to remove and replace the manifold. No blood loss from cuts.
Fingers fit between the runners to install the bolts, no long extensions necessary.
https://www.s2ki.com/s2000/gallery/i...1-dsc01316jpg/
I removed in total the smog pump flange and some bosses.
There is a large amount of aluminum that can be removed from that area.
https://www.s2ki.com/s2000/gallery/i...2-dsc01315jpg/
The braces are modified and removed.
The coolant flow parts were removed from the front of the manifold.
I only burp the coolant at the firewall. Works great.
https://www.s2ki.com/s2000/gallery/i...7-dsc00056jpg/
In this bottom view, all of the casting excess was removed from the runners.
Now it it easy to remove and replace the manifold. No blood loss from cuts.
Fingers fit between the runners to install the bolts, no long extensions necessary.
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