Custom 5SFE Intake Manifold Project Options

[doory100]

Got this off a 97 3sfe rav4. I'm going to customize a intake manifold body for it at my work(custom sheet metal shop). this is the starting process should look close to a beams intake when in done. Ill be using 0.100" 5052 aluminum for the body with a machined 0.250" T6 aluminum flange. I will most likely make 2 when i take the intake form my 95 GT off. So I'll have one for sale then. Any thoughts??

This post has been edited by doory100: Oct 6, 2014 - 7:40 PM

[Bitter]

The ports in the head and the ports on the manifold probably match somewhat closely on the intake, but you may be surprised when you lay the gasket over both to see that the metal overlaps the gasket noticeably. I port matched the exhaust manifold on my 2ZZ to the exhaust gasket which left an anti-reversion lip all the way around the port on the head (I didn't touch the head). The 2ZZ in stock trim is a fairly healthy breather, even without anything gasket matched. The 5S is likely similar on the intake and exhaust. My 7A exhaust ports eclipsed the gasket a fair amount as well...easier to cast things a little small I guess.

If you're hogging out the ports in the head, go as big as the gasket openings then port the runners to match, however cast runners like that are very rough inside and there are often 'nodules' of aluminum sticking up and areas of severe roughness that hurt flow more than you think. You should get a flexible shaft and some flap wheels and get up in there and smooth it and hog it out some.