AGearHead4Life

iTrader: (5)

This is a video of my 5.3 truck intake being shaved using the process of plastic welding to close the holes. Also, all of the vacuum ports and sensors are relocated to the rear of the intake. Truck has been driven for a week now and everything looks good.

This plastic is some strong stuff. I tested the strength by welding two pieces of scrap together and then trying to break them apart. I could not do it by hand. STRONG! I also knuckle punched each hole I plugged and they were solid.

Here's the vide. Enjoy!

mosawi

Gr8 job ����

parks450

iTrader: (17)

Wow, you have much patients. Killer job man

brandon6.0

iTrader: (32)

Looks good. Plan on painting it?

AGearHead4Life

iTrader: (5)

Thanks guys!

Yea, later on I plan to pull it off smooth it better and paint it to match the truck. I may also cut it in half to port the inside.

gMAG

iTrader: (1)

Mark, another great job! I've just duplicated what is on your LS1 Head Porting Video on my 806s. Can't wait to get it back together.
You have more "patients" than the hospital!

jlcustomz

As someone else who has plastic welding experience, I'm happy with your methods & results. You worked the material down at the joints & filled over, which gives good penetration & enough thickness to sand without worrying about being too thin. Plastic isn't molecularly as strong after welding, so any extra thickness sure helps durability.

I eventually want to get back to my project of making an aluminum top cross ram dual plenum intake attached to an ls1 base I cut down to attach to with silicone hose. But if I don't ever get closer to having enough time, I may just port & shave a truck intake

AGearHead4Life

iTrader: (5)

haha Thank you gMAG! Awesome about your heads. If you remember, shoot me a PM on how they perform once you get it together. I'd love to hear about it.

AGearHead4Life

iTrader: (5)

Cool! Thanks for the feedback jl! This was my first time welding plastic actually. So your input is appreciated.

I most definitely understand that lack of time issue. Scrounging for time to build is hard. Sounds like a cool intake project you've got going on there. Got a build thread yet? I'd like to see it.

I also want to build an aluminum lower intake manifold to sit a GT500 supercharger on top of my 5.3. I believe I saw a BMW here on ls1tech that had done somethings similar to what I want to do.

jlcustomz

For a supercharger intake you could always partially cheat & chop up a used cast aluminum efi intake like an edelbrock. You wouldn't have to fab the more complex efi nozzle area , at least. Shame you can find sheets of nylon 66 glass filled, a modified nylon intake for supercharger would be pretty cool also. Edit;; I did see some sheet material listed in black 30% glass filled, but super expensive. May check with the local Sabic Polymershapes when I get time.

Don't have any really good build threads going on, as most of my work, including the plastic welding project of the 2010 Camaro nose conversion in 09' was before my being on the internet days.
http://gbodyforum.com/viewtopic.php?...7#.U5pJUCxOWJA

Even got the nod of approval from a gm engineer on my intake ideas.http://www.pro-touring.com/threads/8...+plenum+intake

AGearHead4Life

iTrader: (5)

Sounds Cool! Thanks for sharing. I'll check those out.

ON the intake that was kinda my first idea, to just chop up an existing one, but even those cost a couple hundred. I was able to find a buddy that will be able to fab up the flanges cheaper. We'll see how it goes.

jlcustomz

There are places that offer flanges, but my only thought of using an existing efi intake is to not have to set up to make & get the fuel injection nozzles correct for a 1 time project.https://ls1tech.com/forums/forced-in...y-ls1-bmw.html

I called the local sabic plastics distributor today, waiting on an email back about nylon 66 30% glass filled sheets. Could be handy.

Firebirdmuscle

iTrader: (16)

Awesome job. Gotta love it when you take your time and your project comes out how you planned.

AGearHead4Life

iTrader: (5)

Yes! That is the thread that my ideas are feeding off of. That was an awesome build he did.

I was thinking the same about the flanges and injector bungs but figured I'd try it with stately of more labor then cash. I've gotten the bungs already.

AGearHead4Life

iTrader: (5)

Thats it! Thanks Firebirdmuscle!

AGearHead4Life

iTrader: (5)

I've added a couple still images to the first post.

poughcujiayi

Wow, you have much patients.

ecir45

iTrader: (1)

Just an idea on the rear plug where MAP is relocated.

This guy says intake is made of nylon 6/6.

https://ls1tech.com/forums/16290469-post59.html

Thinking cutting rear oval plug to the flat then buying some nylon 6/6 sheet 3/8 or 1/2 thick to weld it in place of. Should make a nice large flat area to drill and tap or weld too for vacuum ports.

MAP should fit into a drilled 3/8 hole then make a hold down bracket for the MAP.

pdlightning

iTrader: (1)

Great job. Excellent video. We all thank you:

AGearHead4Life

iTrader: (5)

Here's a couple videos with the engine running with this intake on. I'm still learning to tune but Its running decent.

Walk around and engine close up right after swap video:

Test drive video: