DIY Fiberglass intake/plenum.

[Clare Snyder]

HeinGer at aol.com wrote:
> 
> In a message dated 98-02-13 05:57:50 EST, you write:
> 
> << By the time that all this has been done, would it not have been easier
>  to form a mold from high density foam and polysterine, and cast an
>  aluminium manifold?  The equipment needed to do this would not be that
>  specialised, as we used to make casts at school when I was 14 years old.
> 
>   >>
> The stuff you were casting when you were 14 wasn't hollow.  Don't forget that
> a mold for casting something like a manifold requires both inner male plugs
> and outer female molds.  To do that, you need a pattern that is a facsimile of
> the final part, ie a fiberglass mockup.
> 
> Heinrich Gerhardt (Mr. Goatwrench)

How about a nice foam pattern? Make it in 2 peices, and glue it
together. Then "cast" your mold around it, and melt out (heat or
solvent) the pattern. It is called lost foam casting - used by Saturn to
cast virtually ALL their aluminum parts. Take a look at a Saturn block -
you can see the styrofoam texture.
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