I'm starting my project.

Basically I'm going to use the allante lower intake manifold and allante fuel rails with my 4.9L fuel injectors, and a custom upper intake.

I bought the lower intake with thermostat housing and fuel rails for $150.
I also bought two and a half feet of 4" exhaust pipe for the plenum, and four feet of 1.5" pipe for the runners. $20 at local exhaust shop.

plenum pipe with allante gasket

I'm going to cut the ends of the eight runners to fit the contour of the plenum, and then weld them on.
Then weld on end caps, and a flange to the other end of the pipes to clamp to the lower intake.

I'm still not sure if I will put the throttle body on one of the ends, or if I will put it off the middle of the plenum. It depends on how it fits. I'm going to make the runners 4-5" long. The longest I can make them without it hitting the decklid. Right now I think I have 8.5" from the top of the throttle bores, to the decklid. I expect at least 20 hp, and maybe 30+ up higher in the rpm range.

this is almost the exact thing i was going to do. be careful about distributor cap clearance. you dont wanna have to remove the intake every time you have to change the cap/rotor....

maybe put a nice sweep to them so they will be out of the way? like off to the side.....

OR do like a v6 taurus sho and make the runners variable length with a motor to open a set of butterflies......
i think i am overcomplicating things.....

nevermind me...

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Brandon Edmonds

1996 Taurus SHO (my baby)
1986 Ford EXP (goin bye-bye soon hopefully)
1986 Fiero (to be my street rocket)
1977 yamaha xs750-2D (in pieces right now, doesnt appear that it will be done for summer, unfortunately)

thanks for the advice, I'm gonna cut the pipe to length, and then see where the TB will fit without making maintenance a ***** .

In case anybody is still wondering 4.9L injector rails don't fit right on to the Allante intake manifold. The injectors and the two side rails fit on but the mounting tabs are in different places, not too hard to fix. But the big thing is that the pressure regulator hits on the raised center part of the manifold.
I laid one of my spare 4.9L rails on my Allante lower intake today and discovered this. The pressure regulator would need to be moved about an inch to clear the manifold. Don't know how hard this would be to do without kinking the tubing. Although it is pretty thick stainless steel, maybe it can be bent enough to clear. Maybe if I can't find Allante rails I'll give it a try.

Dragon1/Brian

hi brian, I did not know you were adding an allante intake also. You have a PM.

I got my lower intake and fuel rail today. $165 shipped. They also included the injectors and harnesses! (They said they were not going to)

Unfortunately, the metal gooseneck on the end by the coolant housing got bent in shipping! Now what?
Can this part be replaced?

I can see the other end of it in here.

Cool project.

If you're making the intake out of mild steel you better have it coated before you put it to use. Otherwise it'll rust inside. You don't want to be sucking rust into the engine.

Better yet, after you build a prototype out of mild steel then duplicate it in stainless or aluminum.

If it works out to my satisfaction, i planned on making another in aluminum with improvements over the original. Thanks for the advice. I'm so excited to get started on it this weekend. Luckily I have a junk engine I can use to do the mockup on, and make sure everything fits, and I'll still be able to work on/remove all the maintenance iems.

I wouldn't even worry about that little dent, it won't hurt anything as long as it's not kinked or flattened completely. Did you get any of the fuel line at all. I guess the "fuel in" line that goes to the top of the fuel rail is very expensive if you don't or can't get it with the intake. It has a special fitting and clamp to hold it to the rail. I got a lower intake two weeks ago and my fuel rail came on Thurs, it didn't come with the described fitting so I'm still looking for it. I got lucky the other day, went to the Cadero group on Yahoo and Greg Duncan, one of the originators of the Allante intake swap had just put a whole assembly up for sale. Needless to say I bought it. So I now have a complete assembly and an extra lower intake and fuel rail. Hmmm, maybe after I get the intake on my car and running I'll use the spare intake to mock up a M112 supercharger setup......

Dragon1/Brian

It looks like I didn't get that piece!

Here some pictures of the fuel rail.

[This message has been edited by collinwestphal (edited 11-13-2004).]

Picture number 3 is the inlet port, you got the two clamp screws but did not get the clamp or the fuel line with the fitting....the search begins......
I'm trying to get one from Elite........

Dragon1/Brian

ok, got my intake cleaned up real nice today.

The stock 4.9L lower intake manifold weighs 21 lbs including thermostat housing.
The stock allante 4.5L lower intake manifold weighs 20 lbs including thermostat housing.

[This message has been edited by collinwestphal (edited 11-14-2004).]

Any of you guys know if the upper manifold air inlet tubes (from the plenum to the lower manifold) were the same size for all model years?

yes, I believe they were all the same. 1.5" diameter runners

I would like to know how long each of the runners are???? Brian? Pleeeeaase?

I don't have it yet, when it's here I'll let you know.....

Dragon1/Brian

thanks...

any luck finding that fuel line piece?

Not yet, always seems to take a couple of days for them to get back to me....
Do you want me to see if he's got one for you too??

Dragon1/Brian

It isn't much, but it might help with the visualization. The runners have small velocity stacks on them, which consequently prevented me from placing them quickly in the right position, so they're actually all evenly spaced.

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My Web page | The Turbo Super Duty Build.

Very nice FastIndy!

thats exactly what I'm planning! thanks for the drawing. I have decided to do it in aluminum, but I'm still having trouble figuring out how to do the large circle. It would have to be 10" diameter, and about 3 inches tall, maybe a little more. I'm going to calculate the proper runner length, and plenum volume this weekend. Anyone have any ideas about where to get the circular part, or how to make one? Can you get aluminum sheet that will bend that much, and still be rigid enough for the application? I really want to do the circular plenum, but I know it would be a lot easier to do a rectangular plenum.

double post

[This message has been edited by collinwestphal (edited 11-16-2004).]

8 sided polygon for the v8 would be a sweet design rather than a round intake. $.02

thats a possibility too. It may be the next best thing to a circle. The circle would flow better.

this is interesting!

you might want to get in touch with some other members who have been doing custom intakes, i beleive JStrickler has the numbers that you would need to find out what length would best broaden your torque curves.....

you should check him out maybe a pm is in order

here is a picture by opm2000 of the piece we need.

hey brian,

I talked with shane from Elite today, and he is going to go get the stuff off the engines himself tommorrow morning when I call him back. I think he was getting the two of us mixed up! He said a few guys were asking for the same parts. I'm going to see what hewants for a set of the steel rocker supports too while hes at it.

I've been emailing with Terry, he's not to fast at returning emails. I called him from work when I bought the lower intake and then again when I bought the fuel rails, I can't be on the phone too long or my stuff doesn't get done. When you talk to Shane tommorow see if he has a fuel inlet clamp, the two mounting screws, and fuel inlet fitting/fuel line for me also. Did he give you a price on these parts, or does he have to see them first. If the rocker supports aren't too much maybe I'll get a set too.

Dragon1/Brian

[This message has been edited by Dragon1 (edited 11-19-2004).]

I was looking at your design up top there and you might want to move the throttle body to the other side of the big circle....rather than having the throttle body towards the front of the car put it towards the back like the Allante. With it towards the front you are going to run into the hood hinge, you can't trim that to get it out of the way. But if it's towards the back of the car there shouldn't be anything in the way, but if there is it's at least trimmable.

Dragon1/Brian

Brian,

I completely agree with you. I never meant to draw the picture to show how it would be placed in the engine. My plan is to have the throttle body in about the same location as the stock allante did. I just threw that picture up to show how the flow would go, before I thought about placement in the engine very much.

BTW, I called this morning, but shane was out running parts, and I got Terry instead. I would rather deal with shane, since he seems to quote lower prices, and I dealt with him before. I'll try next monday. I would love to meet tomorrow, but it is the opening weekend for the deer season.

quote Originally posted by collinwestphal:

Is that blue thing a real GM assembly pallet?

I believe I was aiming for 5000 rpms in those calculations. That blue transmission holder is a Kent Moore holding fixture. Unfortunately, it does not fit the reinforced V6 cases. Only the 4.10, and 3.32 cases. They may have made one for the V6 too, but that is not it.