Ford FE Inline Carb Intake Manifold Lost Foam Casting Part 1
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- Опубліковано 7 вер 2024
- This video describes the process used to make an intake manifold designed from scratch and using the lost foam method to cast the intake in my home shop. It’s a little longer than my usual videos but it touches on all the process steps and by the end of the video, the intake is finish machined and ready to be built into a complete induction system to be used on Ford FE series engines. There will be a Part 2 video of the same title in the near future that describes the complete ready-to-run system so stay tuned for that.
The most frequent questions I receive are about pattern and coating materials. If you visit and subscribe to my channel, you will find videos dedicated to those and other related subjects and projects. Those videos will provide far more detail than I ever could in a text response.
• Pattern Materials for ... - Pattern Materials
• Refractory Coatings fo... - Coatings
• Reusable Pouring Basin... - Pouring Cup
351 Cleveland Intake Manifold
• 351 Cleveland IR Inlin...
• 351 Cleveland Inline A...
Boss 302 Intake Manifold
• Lost Foam Casting an A...
• Lost Foam Casting an A...
• Lost Foam Casting an A...
My website: www.inlinecarb...
or the casting forum forums.thehomef...
Thanks for watching…..
Best,
Kelly
Outstanding work Kelly 👍
Had to show the wife the video because she ask me "why are you crying?"
I told her because i want your set up for Christmas 😂😂😂
You can do it. Eat the elephant one bite at a time and work at it....you'll get there, and it's a place worth getting to. Best, Kelly
It blows my mind what awesome castings you make at home, again! What a strange engine with pushrods going through part of the inlet manifold.
That message is a big part of the purpose of my channel, that being it can be done, but will take some commitment. Thanks for watching. Best, Kelly
The FE intake design was done to meet the racing rules back in the late 50's to early 60's . Basically if the cast iron intake was to be replaced with a lighter material intake (aluminum) the Ford engineers wanted to maximize the size of the replacement so 25% or so of a head was part of the intake manifold.
@@JD-fx1mb I didn't know that. Pretty big impact on the guys with wrenches though. Best, Kelly
That system is like ART WORK. EXCELLENT WORK 👌
Now certainly hope it's going on a roller cammed 427 side oiler with the large carb and onto a dynamometer so folks can see an 800 plus horsepower 427 naturally aspirated 👍
Beautiful model, Kelly. And you say that the learning curve was steep but you"climbed up that incline" in record time. The model you designed is not easy to do.
Ahh, high praise from my sensei! You went above and beyond the call providing learning support to me my friend. -So much appreciated! For those looking to develop your CAD skills, Konstantinos is a CAD virtuoso. Check out his channel @ExMachinaEngineering and support him on the TooTallTony leader board. Best, Kelly
@@kellycoffield533I think you just made me look good as a teacher because you wanted and could learn. I gave you a direction but you ran the distance.
All of the runner design, parting line, and split models, and CAM specific models you did completely on your own after all.
That is one hell of a set up you have going on there. Great casting
The very first picture of your CAD design I had to hit the pause button and leave a comment, how you drew a circle and had a series of sweeps down to the face of the port was worth watching the video! Absolutely AWESOME! Your work looks so original right down to the logo and part number. I can't imagine how much that manifold would cost with the amount of work that goes into the foam mold. Truly a labor of love, Are you going to make an additional lower section that goes on the block in the future? I was fortunate to work on a lot of rare Ford race parts 40yrs ago and they where already rare even back then.
It did take me a while to figure out the CAD modeling techniques but was well worth it. This intake was purpose built to fit the FE Power FE intake adapter but there will be a 351c and Boss 032 version with integral valley pan. Thanks fr watching. Best, Kelly
Performing an excelent work makes a man happy, well deserved,mit looks brilliant!
Very nice work Kelly. I have seen two of the inline carbs in the past 45 years . The first one was back in 1978. the second one I tried to purchase but the owner would not part with it.
I’ve only got a few words to say to you:::: absolutely awesome you are such a clever guy I wish I knew half of what you did how to do the computer work unfortunately I’m useless on computers I have to do everything by hand and Eye . A fabulous job and a pleasure to see many thanks for sharing 👍👍👍❤️
Would love to see @lykinsmotorsports build and test one of his FE's topped with one of these. Beautiful work as always Mr. Coffield.
Ya never know....😇 Best, Kelly
Wow just absolutely amazing casting especially done at home 🏡
Such craftsmanship is fantastic, enjoyed watching the process.
Nice job. You have obviously put a lot of time, effort, and money into this.
Not afraid to spend but more weighted on time and effort. Best, Kelly
Absolutely amazing! Well done!
This is amazing, well done ! Thanks for sharing. Makes me want to get back out in the shed 😁 👍
Amazing work!
Just awesome, you have inspired me to get the devil forge, it’s small and I’m yet to test it but man your parts look just amazing! One of these days I wil” try to cast something for my old Ford.
Absolutely incredible.
New follower here and fellow Cleveland Enthusiast.
Clevelands Forever!
This is just ridiculously awesome!
This is amazing to see your work man. All completed at home lol. I just randomly ran across your videos and will look forward to more. Keep up the great work sir 👍
That is such a high tech home casting setup good lord. Great PPE and everything. Even hoisting the crucible with the crane. Makes my engineer brain happy
What a wonderful gem of a channel to stumble on, you've earned a sub 👍
that looks fantastic... wow. Got me thinking about my Fusion360 and my Avid CNC and home depot foam board.... lol
I definitely can see the advantage of doing a prototype in foam. Verses making a pattern in pla off a 3d printer. You have to deal with shrinkage of plastics. Cad designing is the hard part. Both take time to run. That program to see your tool paths in action would be a savior. Great work I know you’ve spent hours doing your education but it has paid off.
These are so good it seems as though there should be a small secret mark on them. Like a circled rocket or something that designates them as yours, for those in the know, but would simply be a mystery for anyone else.
just came across this channel might be one of the coolest on youtube
MAN...... this is really good content. Thanks for taking the time and effort to take us along on this project. I have done a little simple pattern casting / machining and just got into lost foam casting to make engine to trans adaptors. I was really impressed with the lost foam process, but this is state of the art, Light years ahead of what I did. I would be very interested at trying my hand at CNC carved patterns at some point in the future. People have no idea the engineering and thought that goes into something like these parts.
Please keep this content coming and thanks again
Glad it was helpful. The primary message of the channel is lost foam is a practcial method for hobbyists to make larger quality castings at home. It'll take more effort than watching one video, but certainly can be done and is a place worth getting to. Best, Kelly
Outstanding! Very very cool. Thank you for taking the time to share this with us
You have some special skills my man!
This is outstanding work. I make parts that go to space and I’m honestly humbled.
I've been looking all over for these. You sir have unobtainium. You have the thunder of the greek gods of muscle cars! I'm glad you made this video. Barry Grant modeled the "Badman" Inline carb after these!
ShOcK & AWE You "R" the "Casting Whisperer".. A treat for the eyes and joy to last forwever. Cheers from So,CA. 3rd House On the Left. p.s. I spotted a ad for a casting call in Hollywood - Yeah, it didn't pan out. My bad.
Casting Call? I like that one.....think I'll borrow it 😀 Best, Kelly
Very cool Kelly!!! I’m a big FE fan and my second fav is the 335 stuff. It’s neat to see people (like your self) are keeping it alive.
I just found your channel. I've long been intrigued with these carburetors since my dad told me about the one he had on his stock car in the early seventies. He used to race superstock class with a Boss 302 built with Ford's special Nascar rods, pistons & titanium valves. This was up here in southern Saskatchewan, Canada. I so wish he had kept that stuff. Can't imagine that there were very many shipped up here in those days. One of the things he noted from that setup was the awesome sound that the cross-boss intake made at high rpm. There was nothing else like it at the track he said. Really cool to find out that somebody is still working with these!!
Were the titanium valves a Ford part number ?
@@jesse75 Yes. They were genuine Ford off-highway parts
@@jesse75 I still actually have one exhaust valve from that engine. The bottom face of it is also dished, rather than flat like the stock unit. The stem is straight cut down to valve head, rather than having that thickened portion rear the head like stock has. They are MUCH lighter. They were available from Ford's "Off-Highway" parts manual back at the time, which I also still have.
@@FiteTheGoodFight thanks for the answer. One reason I asked is a couple years ago I bought a vintage built race car.
The car is a 67 fastback mustang. Race modified.
The engine is a 1964 427. As soon as I got the engine home, I pulled it and took it apart.
The valves were 2.19's titanium intakes. On the side of the stems there's a Ford oval stamped or engraved or printed on them. The exhaust is also marked.
They were the 3/8 stems and not the 11/32's.
Did you ever see the valves out of the 302 and were they marked ?
You can see and hear the engine running on a utube video I put up at :
" 427 FE with a new set of valve springs "
I'm trying to trace and figure out all the parts in the engine and try to figure an exact time frame when the engine was built.
@@jesse75 Interesting. No, the valve I have here was swirl polished, so no ford logo on it. I only have my dad's testimony that it was a ford part. It is the 11/32" stem.
Very well done video . I’m a new FE guy . I’ve been working on my ‘64 Galaxie for a year and half now , and learning all that I can.
Very impressive, Kelly. Where do you find XPS that thick? Gluing 2-inch panels creates a problematic seam for me. Thanks!
Commercial roofing contractors use thick XPS. You need to ask about the product and density. The high compressive strength stuff mechanical contractors use under concrete can be too dense but the roofers use lower density board. Flotation billets are also too dense. Best, Kelly
Thank you Kelly!!!
Looks Great....... I know someone that has one of those Carbs. Ran it on a Boss 302.
Thanks for taking the time to post your projects and explaining in detail.
Just incredible videos and craftmanship!
I really enjoy watching your operation. Do you have a website where you sell your castings?
Well not exactly, but yes for the Inline Carb stuff. www.inlinecarb.com. I'll be doing a major rework of this website in the near future and these systems will be available there. I'm an admin at www.TheHomeFoundry.org. You can become a forum member for free casting advice and community support there. Thanks for watching. Best, Kelly
Your forum never sent me confirmation mail
@@farhanchoudhre6962 Let me know the user ID you intend to use and I will watch for you. Sometimes IP addresses get flagged due to other activity and that can result in a rejection. Best, Kelly
That is some very trick induction! I do like the idea of spreading out the fueling and that theory does seem to work well with proper tuning. I've run dual quad AFB's on Big Block Chevy for this same reason and was able to lean them down way farther than with a single centrally mounted carb for good fuel economy as well as power. My hat's off to you Sir!
what a beautiful piece! thank you for sharing...
I am always astounded by the quality of your work. How come your castings do not erupt anywhere near what others seem to suffer from?
Keep on supplying great videos!
I've worked very hard at that and there is not a simple answer. I believe it's a combination of a number of things. Part design, feed system design, pouring cup design, and coating permeability. Most of my parts are relatively thin walled and have lots of surface area compared to their volume. This along with the permeability of the refractory coating means the evaporating pattern gases vent very well to the mold. The sprue and gating system design using low density foam with high pattern contact area and sprue height produce good head pressure and generous area to more uniformly feed the part, and lastly the shape and depth of the pouring cup help prevent turbulence, immediately covering the sprue with 4" of molten metal establishing a tranquil and orderly fill of the mold. On the latter, many people allow the sprue to protrude well above the sand surface in a round can. That exposed sprue immediately ignites and floats beacuse it is exposed to air and usually wreaks havoc in the cup as more metal is poured on top of the burning polystyrene fuel whereas my pouring cups sit flush on top of the sprue. I was amazed how much cup shape seemed to help. Round cans/cups and sprues tend to aspirate air due to coriolis affcet, whereas square offset cups and square sprues do not. Best, Kelly
@@kellycoffield533 Wow! Thank you very much for the very detailed answer and taking the time to reply.
Awe inspiring work!
Hi Kelly, I'm always looking forward to your downloads, thankyou for your thoughts!
Rich
Awesome project an crafstmanship!
This is FANTASTIC ! Absolutely Beautiful parts ! Congratulations !
fantastic…
in case I missed it; quick question?
cnc cycle time per part (roughly)?
look forward to your videos.
For the center spyder section it was about 90 minutes/side x4 (two side for two pieces). I really didnt make any effort to optimize the run time. Just set up flipped the switch and went and did something product. With work it could probaby be half that but doesnt make much sense to invest the time when you're only making a couple pieces. Best, Kelly
Beautiful work!
Verrry tasty stuff.. MMMM GOOD ,!
Unusual stuff is almost perfect... and LOOKS VERY PROFESSIONAL..
TESTS AND REVEW..?
Wow, this is just fantastic.
I want to learn how to do this! Would love to be able to cast my own intake runners and valley cover to mount downdraft webers on my 5.0 H.O. among other blue oval dreams
as always very impressive work!
A 671 style blower adaptor on top would be awesome!
Great job!
Super interesting!
Kelly thank you so much for all your videos. Here, at about 8:50 you speak of a post-processor for CAMbam's output without naming it: is that just the CAMotics or another package? Your insights about zero draft and parting line location, just to mention these, are really appreciated. Please keep them coming.
I use CAMOTICs g-code simulation software to prove out the CamBam CAM programs before I cut patterns. It can be downloaded for free (search it). The MillRight CNC router controller is GRBL based which is also open source. I use the GRBL post processor that was provided with CamBam CAM software with a mod to how it reads and executes arcs. That mod was done by a CamBam forum member for me. Ever since then CamBam spits gcode that works flawlessly every time. Best, Kelly
Wow!
Really good job!
Nice job.
You could fool any Ford expert with your castings. 50 years ago, I wondered what a side-oiler would run like with 1 or 2 Autolite inlines on it. It's great that you use your artistry to produce historic automotive artifacts that never existed.
The greatest intakes never made.... 😁 Best, Kelly
Great video
this was pretty impressive. welldone
Do you have a book? Your knowledge on how to achieve this quality is amazing. I know some of it is in videos but...wow
No book, but kind of a lessons learned thread. forums.thehomefoundry.org/index.php?threads/confessions-of-a-lost-foam-caster-5-years-on.1650/ It's a little dated and needs an update. You will need to join the forum to see full size pictures. Best, Kelly
Love it Kelly, great job.
Thats bad ass wow its definitely what you know get it done great job 👏🙌!!
I assumed you don't use aluminum cans for your pour. What aluminum do you use?
A356 Aluminum Ingot. Best, Kelly
Fantastic. Can You give me your email address please?
One of my friends takes all my used pistons from engine rebuilds and melts them down to make parts for cabinets and wood work.
So awesome!
Your work is gorgeous!
Great job, thanks for sharing 👍
Very nice Kelly....I have a 427FE in my 68 Mustang and I have one of Jays very first adapters. I also have a 67 Mustang T/A replica and I am quite aware of the inline autolite ...Thinking it would look very nice on my 427..
I suspect everything looks nice sitting atop a 427 in a '68 Stang 😀. Best, Kelly
Stunning work 👍🏻🙂👍🏻
👍👍😎👍👍 always impressed with your work.
What do you do for a living? Very good work.
That turned out great. How much do you scale your model to account for aluminum shrinkage? Thanks for your content
101.3%. In other words, .013 units/unit. Best, Kelly
I didn't know about your channel before, but this intrigued me and looking through some of your other channels, you are an EXCELLENT guide to the whole process of "lost foam" casting.
When you do the break-out, if you spread a plastic sheet down first it makes the clean-up much easier, and keeps the sand clean for re-use.
I'm not THAT familiar with the FE series engines, but is there actually a reason the pushrod holes NEED to be left as holes, rather than just maching away the 'bottom' parts - slotting them - so it can be lifted off with out interferring with the pushrods?
Hopefully you find the channel helpful and useful. Plastic sheet would be melted by the hot sand in a split second. It will also melt the thread that binds the soles to your shoes 😉 I resue it many, many, times but at $20/ton it's not much of a concern. Best, Kelly
@@kellycoffield533
Good point, - maybe some sheet metal shaped like a tray, with a spout at one end/corner for pouring it back into the container?
There was a bit more I added to the initial post, too.
Dang, that's cheap, I love the prices you chaps have over there.
@@gordowg1wg145 I have a large drip tray from my automotive lift I use when the pavement is wet. Best, Kelly
Amazing work! Thank you for sharing. Curious about the wax appliqué. Did you make that too and how?
I pulled a silicone mold from an existing part, then melted and poured wax using is it as an open face mold, strinking off the surface with a razor blade. When cooled, I gently flex the mold and extract with a pick and tweezers. Then apply white PVA glue with a tooth pick and hand place the applique on the pattern. Best, Kelly
Hey Kelly! I'm a young engineer, and have really enjoyed watching your videos as inspiration/education for my own projects. I haven't found it yet (maybe I need to watch more) but I'm wondering what slurry you use for dipping?
SEarch my channel "Refractory Coatings". There is a video dedicated to the subject. Best, Kelly
@@kellycoffield533 thank you!!
Very nice ! , I like the way that came out . Something like that intake would even look good on the 5.0 Fox body mustang engine I am putting in my 66 F100 , those old 5.0L fox body intakes are ugly !
Hey, was asking if you'd try to do a miniature V8 engine block casting just to see if its possible? Like one of those Toycan engines. I'm interested in this type of stuff for custom car parts at home but was wondering if it was useful beyond intake manifolds and turbos
I do have a model of a Ford 427 SOHC Cammer.....but have a lot of other projects on the go. Some day maybe. Best, Kelly
I wonder if there's a crucible with a valve on the bottom. You could melt you aluminum above your mold and then drain it into the sand once it was hot. The pour seems like an accident waiting to happen. I tried to read about your oven but the link is broken.
Thanks for these great videos
What glue do you use to join the foam parts?
Also what refractory coating do you use?
Thanks
Watch these videos: ua-cam.com/video/T2H8UH3TeaM/v-deo.html ua-cam.com/video/LdgGkqvk5mc/v-deo.html Surf my channel for more.
@@kellycoffield533 Thank you sir
Can you make a carb intake manifold for the Porsche 928 engines?
One of my friends takes all the used pistons from rebuilds and melts them down and makes parts from them.
Are you offering Intake Manifolds using the Inline Four Barrel for sale? If so have you done one to use on the 302 Windsors with a 8.7" deck height?
8.7" deck? No. But I do have Windsor options available in 8.2 and 9.2 deck depending upon your cylinder head and port location. They are based on Trickflow EFI lower manifolds with a custom plenum and carb adapter. As far as just the intake manifold casting goes, they can be quite a bit more economical than a full custom casting depending upon how you want it finished. Ifthat's of interest you can contact me through www.inlinecarb.com or at the forums.thehomefoundry.org/index.php forum. Best, Kelly
@@kellycoffield533 My bad I hit the wrong key sitting here in the dark. When you're over 70 the eyes don't work so good.
Can you do airflow simulations with any of the software tools?
Previously had access to CFD software but no longer do. Have crude orifice plate flow bench. Best, Kelly
Someone should market an EFI version of the inline Autolight carb. It would sell like hotcakes.
Cool now make one for my 312. Just kidding. I have a factory 2x4 intake.
Not out of the question....but not next. Best, Kelly
Do you plan to polish the inside of the castings? Of the manifold that is.
No. I sanded those surfaces on the pattern before I cast them so the as cast finish is quite good compared to most commercial castings. Best, Kelly
Sorry if you already said this somewhere but do you model these parts the actual size and then increase the size by some constant in the cad software to allow for shinkage.
I increase the model size 1.3% for shrinkage (global rescale to 101.3%). It's the very last thing I do in my CAM program before I cut the patterns. I could do it in either my CAD or CAM software but I prefer to work in the native dimensions which are more recognizable to me. Best, Kelly
Just wondering what you use to coat the foam with?
I think it's called suspendaslurry or similar.
Is tais foram EVA? thank you
Sorry, I dont understand "EVA".
@@kellycoffield533 better, do you use xps foam in your projects? Thank you
@@cncbrasil3507 Yes, XPS, EXtruded PolyStyrene insulation board. 1.3-1.5lb/ft3 density. Best, Kelly
Thy name is " Vulcan "
"it's a decent casting"😂. That thing looks like it doesn't even need any finish work
Main plenum body needs more volume.
Don't know how you can say without knowing the engine spec and intended duty. I think it's about right for the typical customer. FWIW, it has as much or more plenum volume than any aftermarket single plane open plenum conventional four barrel intake, and in any case, is easily changed with spacer between the intake and lid, asis the distance from the throttle plate to the plenum port windows, which is why it was designed as it was. Best, Kelly
After doing a quick search I was not able to find out whether or not anybody had made a manifold that carb to fit a flathead Ford V8. I couldn't find a mention of any, so I recon nobody thought of it, which seems a little strange. This old cogger thinks one of those inline carbs would look cool sittings on a flatmotor.
At 875 cfm, it's big for a flatty. Best, Kelly
Software cost comparison en.wikipedia.org/wiki/Comparison_of_computer-aided_design_software
Beautiful work! Impressive!