I made a nice intake manifold, that is still working well after
almost seven years.

I started with a three inch square aluminum tube, 1/8 inch
thick,
about one foot long.

I cut the holes to match the engine intake ports, and the
carb base on the top.  One of the mount holes goes through the
square tubing, the other three bolts just clear the outside
edges.

I filled the tube with urethane foam insulation board, two
pieces
one, one inch thick, the other two.  I then carved the ports and
runners in the foam, and glassed them with two plies.  The foam
supported runners then slide in the end of the support tube,
and I sealed the ends (I used fiberglass, but aluminum would
work better).

I did reinforce my carb flange studs, with 1/2 inch wide by 1/8
inch thick steel strips, which were tapped for the studs.

I worried about the exhaust being too close to the intake
for fiberglass alone.

I have plenty of that tubing, if anyone wants any. George Graham
Mazda Rx7ez N4449E
Homepage <http://bfn.org/~ca266>

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