Lets get back to intake. It houses an stacked intercooler, two different coolers build in one set of headplates. So it needs end tanks to core and way of coolant get in and out. Let build those.
Core was designed and build by leading company in UK. Now days part of PWR group, as is C&R in US. Designed for 2000hp and huge supercharger pushing a lot of air as states earlier. Length of the whole intake and this kind of V10 has long intake. Amost 2 ft.
Core is 500mm (19.6" long), 100mm (4" wide) and 92mm (3.6") thick.
End tanks are milled from 20mm (just over 3/4") thick bar of billet, they have center wall dividing two sides. Draw up and made toolpaths.
Next was coolant connections, they where also easy parts, just machined AN20 male fitting on a lathe (manual), two different length so nut can be easily tighten. Other end has shoulder recess to fit the end tank opening, easier to weld on both sides. Now on later date, these are going to chance to modern push'n'lock automotive nylon fittings. Don't have room for big AN-fitting. You'll see when we get there.
So how to seal and be serviceable. Designed pieces of the manifold to be lifted off, allowing core to be lowered in its place, sealed with O-ring, bolt to place, another end plate out side, houses special polyurethane seals for the AN studs and O-ring to seal to manifold.
Machined it little rough tool paths on purposely to give it some texture. Mounting with sunked M8 allen bolts. Made plates to both ends of the intake, now coolant can be connected many different ways to it.
When welding all together, core will have side plates that will devide hot (center) off from cold (sides) side of the intake by simply been welded to core and bolted through top plate. After talked with the swedes, desided to machine extra space on bottom side of the top plate of the intake. milled off 5mm (almost 1/4") from hot side to give room to breath.
Enjoy,
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, Juhani
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