Intake manifold construction

[Seth]

The DGEBA epoxy you are likely to use is not good for much over 100
degrees C. You could get a tooling epoxy, but even that is probably not
any good at 150C.  If you could get a flange of steel or aluminum and
extend it up a few inches, then graft on a plenum and runners of glass
and epoxy, that might keep the plenum cool enough. If it's a crossflow
head, then the intake will be cooler. If it's a single port face head,
then you may still encounter heat problems.  You might consider a
phenolic/glass composite flange, then graft on the runners and plenum.
The phenolix matrix will put up with the heat, and won't conduct enough
to do the epoxy/glass any harm, IMHO.  There is still the issue of
underhood convection at shutoff, however.

-Seth

Sean W Walsh wrote:
> 
> Can anyone give me a reason why I shouldn't construct an intake manifold using
> Glass Reinforced Plastics?
> 
> I have an older 4 cyl lancia engine with a dual throat single carby and 4 branch
> manifold. I'm converting this to EFI and want to create a port injection rampipe
> style intake with a small plenium etc. GRP lends itself to "backyard" techniques
> and since I have a bit of experience with boat construction I thought I'd give
> it a go myself rather than getting something fabricated.
> 
> What are the problems I'm likely to face : different temperature expansion rates
> of the inlet manifold (grp) and the head (alloy)?  fatigue from vibration? high
> temperatures breaking down the epoxy?  I know there are epoxy resins available
> that are rated to 150 degrees celsius so that should be enough (?) any other
> suggestions?
> 
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