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**JohnStranahan** · 01-09-2008, 02:30 PM

I don't have the CAD either. Sounds exciting though. Good luck.
Here is some info on ABS. The softening point is 200 F. (it is possible that they use a slightly higher temp plastic at Ford) So how does Ford keep their manifold from melting. Well it is from non contact and air cooling. The manifold does not really touch the head to any great degree. There are seals that touch the head and the manifold and prevent most contact. There is a natural cooling that ocurs when air expands after the throttle body. There is also considerable cooling that occurs to the intake manifold surface in the head by the proximity of the fuel injection spray.
Consider this an experiment. I don't know if my ABS will stay sealed or not. I suspect that with a gasket similar to what I have shown and blue silicone sealer that I won't have a problem.
You do need to use fastening techniques suitable for plastic. The main problem is that plastic is slow flowing liquid. It will flow away from bolt pressure. This is the reason for the inserts and large section thickness of the manifold that I have planned.

I would certainly try to just print out a manifold. They may even have access to a wider range of plastics than I do.
John
Houston, Texas, USA

01-09-2008, 02:30 PM	#109 (permalink)
JohnStranahan Junior Member Join Date: Dec 2004 Posts: 98	Re: Suzuki GSXR 750 quad Throttle Body Install on 2.3 L Duratec I don't have the CAD either. Sounds exciting though. Good luck. Here is some info on ABS. The softening point is 200 F. (it is possible that they use a slightly higher temp plastic at Ford) So how does Ford keep their manifold from melting. Well it is from non contact and air cooling. The manifold does not really touch the head to any great degree. There are seals that touch the head and the manifold and prevent most contact. There is a natural cooling that ocurs when air expands after the throttle body. There is also considerable cooling that occurs to the intake manifold surface in the head by the proximity of the fuel injection spray. Consider this an experiment. I don't know if my ABS will stay sealed or not. I suspect that with a gasket similar to what I have shown and blue silicone sealer that I won't have a problem. You do need to use fastening techniques suitable for plastic. The main problem is that plastic is slow flowing liquid. It will flow away from bolt pressure. This is the reason for the inserts and large section thickness of the manifold that I have planned. I would certainly try to just print out a manifold. They may even have access to a wider range of plastics than I do. John Houston, Texas, USA