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Ben,
Not knocking your approach, just making suggestions, just couldn't see how you were doing a straight tube inlet as most are curved over the engine. As for the manifold, I'd be tempted to use aluminium here and bond the tubes to it to make a slip joint.
BTW how much is the Aquacore- is it expensive. It may well be corn starch based but cooked to make it machinable.
I found a product locally which appears to be corn starch based( it smelt like it). I used it to make a mould for a motorbike windscreen, turned out really good, however it's really rock hard when only air dried (no cooking required) and wouldn't be machinable as it is also brittle. It's very smooth though, however it's also not water dissolvable.
George (down under)
George,
I had thought of not being able to machine the oval shaped ends on the two center tubes attach points. My idea was to machine it round to the long dimension, then use the stationary belt sander to sand down to the smaller dimension, followed by turning down the length of the tube to the appropriate diameter.
I am not a machinist, but don't see why this approach would not work.
I have a couple of friends that are machinists, and thought I would run it by them.
I may use the corn starch idea to make the plenum for the manifold. I will likely try that simply because it doesn't cost anything. Would be fun to experiment, and may even lay up regular fiberglass over it for a trial run.
Ben
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