I have the opportunity to purchase a rare dual four barrel intake manifold. I'm asking for information on how to make a mold of this for the purpose of casting duplicates.
I'm in Atlanta and visited a small foundry in West Point Ga. The told me the mold would run about $2000 but the casting would be cheaper. That wasn't much help so the idea hasn't progressed any since then.
Ok, so, can I make this mold without destroying the intake manifold? How should I proceed?
Thanks kindly.
bg
IMHO $2000 sounds quite reasonable for the patterns and core boxes needed for a part like that.
If you go with having a foundry make the mold and core boxes for you, make sure you have a written agreement about who "owns" the tooling. It is obviously to your advantage to be able to take the tooling and move it to a different foundry if you wish.
Remember, shrinkage of hot cast metal has to be accounted for, as well as material to be machined off to get flat surfaces, so making a mold isn't as simple as just forming one around an existing part.
Undoubtedly others will have much more to offer on this subject.
Jeff
Are you familiar with the casting process? If not, you need to realize what you are asking is not a trite thing. It is not just a matter of making a mold for the outside of the manifold, another issue is the cores and the core boxes required for the hollow runners inside the manifold. The price you were quoted I think is reasonable for what you are asking. You might get a cheaper quote is you would allow the mold maker to break open your manifold after using castible materials to take the shape of the runners. I just don't think you are going to do much better. Rick
My family has an old Gar Wood with the original 200 HP Scripps marine engine. In-line six, about 670 ci. The original manifold developed some porous spots.
It's more complicated than an automotive intake manifold, I agree. But pattern costs have been $5,000+, and we haven't gotten a good casting yet.
Having the patternmaker work for the foundry, and the foundry guaranteeing a good casting, might be wise.
John Martin
Intake shouldn't get too hot - why doncha just JBweld it all over?
Or is this a purity thing?
More than intake - exhaust as well.
John Martin
Actually, that sounds dirt cheap to me. We have had some molds made for diesel engine heads, and, on even the smaller ones, the mold fees ran about $10k (in China). I realize a head is more complicated in some ways than a manifold, but, still, the patternmaker has to create quite a number of fiddly little bits to get the wall thicknesses right, and all the passages where they need to be. Once you get past that, though, the castings should be pretty cheap...maybe $20 each? - Depending on your volume of course. If you are only going to cast one or two, it is going to be QUITE a bit pricier than it would be to cast a couple hundred. Regards Dave Mundt
Is the name of the foundry West Point Foundry? If so, be careful, they filed bankruptcy, I got stuck for a fair amount. I make some castings for them here in Northern Illinois.
On your questions, you need to use the right terminology; I am assuming the $2000 quote is for pattern tooling.( a pattern and corebox(es). Again assuming that you will be getting a loose pine pattern and split coreboxes, that's probably not a bad price. Your original casting should not be destroyed in making new tooling, the patternmaker will use your casting as a blueprint and make allowances for shrinkage and finish stock.
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