Project *** Polished Inlet Manifold ***
 

I am giving my self a project over the winter to have a go at a polished inlet manifold for my classic.

I know this is going to be a big job for me, but i like a challenge.

I am aiming for a clean polished look with as little on as poss.

I raided my dads shed today for some tools and i have..

Grinder
files
hack saw
drimmel
sand paper
eye protection

standard classic my99 inlet manifold

http://i3.photobucket.com/albums/y92...d/PA260001.jpg
http://i3.photobucket.com/albums/y92...d/PA260005.jpg

this was after around 1-1.5 hours with the grinder and file

http://i3.photobucket.com/albums/y92...d/PA260010.jpg
http://i3.photobucket.com/albums/y92...d/PA260007.jpg
http://i3.photobucket.com/albums/y92...d/PA260008.jpg

the 3 prong bits on the right of the inlet manifold that the spark plug leads go into/black box sits on.

do i need to leave the black box here, or can i tuck it behind/under the inlet manifold when finished?

Good luck, it's hard work but if you get a cheap polishing kit from ebay (about £20) that attached to a power drill you can finish it off a treat. I went mad earlier this year did my induction kit, TMIC and diff guard:D

Well the HT leads are designed to meet the box in the middle with the left leads longer as you look at the block, so at a guess you would have to find longer HT leads from somewhere as it is normally a tight fit anyway. And dont forget the plug connector that goes into the box

im just wondering about feeding the ht leads under/between the legs of the inlet manifold and have the black box under the inlet/behind manifold around the same sort of area as standard. i was wondering if it needed to be grounded at all?

this is a pic of what i have on my inlet at the mo

http://i3.photobucket.com/albums/y92...t/P8180042.jpg

Definately needs to be grounded. Have a look at this website. Tim moght be able to source longer HT leads
Scoobyparts Ltd MAGNECOR 8mm PERFORMANCE HT LEAD SET 40205

Leave coil pack above inlet otherwise you'll have problems with heat.

kk will do

think im going to try and find one of the sand paper flap wheels that go into a elec drill, that should speed the sanding up :)

anything else anyone recomends?

B&Q sell the flapper wheels.

I'm still part way into mine and hope to finish it through the winter months, it's a big job :freak3: but well worth it when you finish. I have some insulated spacers to go back under mine when I change it because I figured if it's coming off I just as well make the most of things.

Good luck with the polishing, I used an air die grinder and some small files from a £1 shop to remove the casting and other imperfections...well most of them :)

http://img.photobucket.com/albums/v4...s/IMG_2955.jpg
http://img.photobucket.com/albums/v4...s/IMG_3225.jpg

have you got any front pics of it trails?

spent an hour or so again to day on it

http://i3.photobucket.com/albums/y92...d/PA270012.jpg
http://i3.photobucket.com/albums/y92...d/PA270013.jpg

photo whore at your disposal :D

http://img.photobucket.com/albums/v4...s/IMG_2954.jpg
http://img.photobucket.com/albums/v4...s/IMG_3226.jpg

Finished article...
http://img.photobucket.com/albums/v4...s/IMG_3462.jpg
http://img.photobucket.com/albums/v4...s/IMG_3463.jpg
http://img.photobucket.com/albums/v4...s/IMG_3460.jpg

Its a big spider :)

edited for accuracy :lol1:

what did you use to gring the bits off the front where the TB is?

brute force:freak3:, an angle grinder and die grinder :)

had another hour or so today with the grinder etc

have got quite alot of the orange peel off now

http://i3.photobucket.com/albums/y92...d/PA290014.jpg
http://i3.photobucket.com/albums/y92...d/PA290015.jpg
http://i3.photobucket.com/albums/y92...d/PA290016.jpg
http://i3.photobucket.com/albums/y92...d/PA290017.jpg

good job, I knew I should have removed that other little wedgy bit :D

i saw that you haddent, so was not sure if there was going to be a hole under it or not.

so thought i woulf be brave and have a go

result :)

^ its quite time intensive but I found it oddly relaxing :lol1:

may be starting again as I'm thinking of rotating the IM while the engine is out :cuckoo:

What the PEG was used for??? :Suspiciou

Good Job BTW :thumb:

I've been trying to get motivated on mine since the summer I got part way in and it did my head in slightly :freak3: :lol1: hopefully now over the winter I can finish it off, far from easy and a ton of patience required for sure.

I simply went for a full polish on a few areas straight off to see how much prep was really needed now I need to work back a few steps then go for the finished polish again.

http://img.photobucket.com/albums/v1...ngine09029.jpg

http://img.photobucket.com/albums/v1...ngine09027.jpg

http://img.photobucket.com/albums/v1...ngine09021.jpg

http://img.photobucket.com/albums/v1...ngine09024.jpg

Good luck there :thumb:

looking good there, mine is getting there, have had a few days off now as it has been wet outside, and i nearly got killed the other day when i started it on the kitchen table lol

have started to go over with sand paper. it is when you get it nice and smooth apart form one or two small scrach marks in the smooth finish that really bugs me!!

Far too much work vs the gain for me guys but hats off to you. :thumb:

you know them little holes you get in the casting when you start to smooth it down, will i had some on the front that were really bugging me so i started to try and sand them away.

and the result.
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ouch :(

am going to see if i can get the front cut out and a new bit of alloy weilded in

bugger

http://i3.photobucket.com/albums/y92...redownload.jpg

^^^ Bugger!!! ^^^

Easy fix mate, dont let it get you down :)

my dad is going to take it to work and see what he can do to fix it. he also wondered what a bead blasted finish would look like, maybe a satan finish.

its all part of the learning curve :)

I sliced through mine when I removed the lump from the top part (angle grinder clutz)...welded and cleaned up and it's good as new. I'm sure your will be fine :)