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Jay's Intake Adapter, On a Diet
frnkeore:
First, I asked Jay about posting this, 3 weeks ago and he gave his approval so, here we go.
As many know, I bought Brent's JJ tunnel port manifold and carbs. I hadn't thought about it at the time but, it is VERY heavy, about 80 lb with 2 10.5 lb carbs. Although the adapter isn't all that heavy ~ 29 lb complete and 25 lb bare, I noticed there was a lot of aluminum that could be removed so, I made a holding fixture, out of some 1" thick scrape pieces. I had cut a plate, years ago to turn round and these were 2 of the left over pieces. The back sides were cut for a snug fit, into the table slots, then drilled 1/2" and counter bored for 1/2 x 13 Allen bolts, 3/8 x 16, were added also, centered on the slot, after that, I made hollow dowels .466 to fit the end manifold bolt holes, that ranged from .470 - .467. It holds the manifold, fairly rigid.
From there, I outlined the tunnel ram ports, on to the adapter ports and started cutting with a long 3/4 endmill, with a 1/16 corner radius. You can compare the picture from Jay's web site, to the cuts I made. There was a lot of aluminum removed. Notice the red circled hole, in the rear of the manifold. That was solid aluminum so, I milled a elongated 3/4" hole, threw to the valley, on each side.
More to come.
Cyclone03:
Nice work.
The “heat riser” area can be cut away if your heads have them blocked. You could also remove material from the side of the pushrod passages maybe just cut them away.
How much weight have you trimmed away so far?
frnkeore:
--- Quote from: Cyclone03 on October 14, 2021, 10:09:47 PM ---Nice work.
The “heat riser” area can be cut away if your heads have them blocked. You could also remove material from the side of the pushrod passages maybe just cut them away.
How much weight have you trimmed away so far?
--- End quote ---
I want to leave this manifold functional for most applications. I'll be 77 next month so, I won't always have the manifold. I know that I could have removed the outside surfaces of the push rod area but, I choose to make it a 1/8" wall. That wall was at least 3/8 thick.
I've taken 2 1/2 lb, so far and I figure another 1 to 1 1/2 on the bottom. So, 3 1/2 to 4 total. The top is basically done, including the valley cover, I modified it by grooving the perimeter and removing metal in the logo area, too. The last operation will be the bottom, it is mostly 5/8 thick and I'll trim it down to 3/8, where I can. The water passage area is much thinner on the bottom, so I'll leave that part alone.
I'm hoping Brent will read this, as I have a question regarding the push rod passages. As shown in 2 of the pictures (1 here and next to last on the other post also), all the push rods were rubbing, in the bottom ~1", one heavier than the others. I'm wondering what diameter the push rods were and if that might be the result of push rod flex. Flex came to mind and if so, that is one of the reasons I to choose to leave the passage there, for added support for flex.
There are a lot of other little areas that I could remove metal but, I don't think it would amount to but, 1/2 lb max and would require different set ups. All this work was done with just the one fixture and I will have to make another for the bottom.
The water transfer passages seem restrictive to me and since this combo may find it's way to the street, I decided to open them up to about 9/16 x 7/8, as large as felt safe in going w/o studying the area.
I forgot to mention in the first post, that this adapter is #006 and was ported by Joe.
blykins:
If I'm not mistaken, the early adapters had smaller pushrod holes. I found this out when I started checking for pushrod clearance and had to spend quite a bit of time grinding for clearance. I think that aspect of the adapter was revised later on.
Any contact would have been because of deflection. I used 3/8" pushrods. Contact on deflection is ok, and it's actually not a bad thing at all, because the intake tube will lend support to the pushrod like this, kind of like a guide plate. Even pushrods for FE roller lifter setups are not short and with 700 lbs of spring pressure and 7500 rpm, they are not going to stay straight.
frnkeore:
These push rod passages are .520, on average, top and bottom.
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