DIY Fiberglass intake/plenum.

[Shannen Durphey]

Clare Snyder wrote:

> 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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  I've noticed that pattern.  I think I've seen it in a Geo Metro (Suzuki) also.  I
can sleep much easier now that I don't have to wonder about it.
Shannen