skirkland1980 Posted December 29, 2015 Share Posted December 29, 2015 I'm in the process of building a custom intake manifold with 6061 aluminum and I'm worried about head flange warpage. I have a spare head i can bolt it to while welding. Will that suffice or do i need a thick piece of steel? If so how thick or should I expect warpage anyway? Thanks. Quote Link to comment Share on other sites More sharing options...
johnc Posted December 31, 2015 Share Posted December 31, 2015 You can bolt it to the head and then weld only 1/4 of the way around each runner where it connects to the flange. Alternate runners 1, 5, 2, 6, 4, 3 - which means you'll make 4 passes through this order welding 1/4 of each runner each pass. You might have to remove and reinstall bolts as you go. You may still have to machine the mating surface flat. A lot depends on how thick the flange is. Quote Link to comment Share on other sites More sharing options...
skirkland1980 Posted December 31, 2015 Author Share Posted December 31, 2015 Cool. Thanks. That's a good idea. I wouldn't have thought to do it like that. Quote Link to comment Share on other sites More sharing options...
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