yup - I was getting ready to do this with mine too. but, that thread for swapping to the 7730 ECM got me thinking I'm gonna go DIS & use the Camaro intake.

quote Originally posted by Pyrthian: yup - I was getting ready to do this with mine too. but, that thread for swapping to the 7730 ECM got me thinking I'm gonna go DIS & use the Camaro intake.

Like the way you think!

well, finally have some time for this, just got a middle plenum on the way, the top hopefully in a few days.
this will be a more radical change, and will hopefully allow valve cover removal.
I will be keeping the parts, just re-arranging them with alot of cutting and welding, and some changes in the internals of the top plenum.
Picture the top plenum with the ports bent down, the middle plenum ports facing out at about a 45 degree angle. the upper plenum will be higher than stock slightly to allow for clearing the fuel rail with the mods for the internal passages.
I'll take a load of pictures so anyone else willing to try this knows what to expect.

quote Originally posted by goatnipples2002: I hope you get a trueleo like gain because if not this is what you should do. It has to be a ton easier than what you are doin now.

i still want to know who made the dual throttle body intake, i think i missed it.

quote Originally posted by Mister:

this is what my intake looks like right now. well, not quite as nice - just got done cutting it up with a plasma cutter.

Here is a thread on the dual TB intake

https://www.fiero.nl/forum/Forum2/HTML/077346.html

[This message has been edited by goatnipples2002 (edited 02-19-2007).]

i want to use the stock intake but how much would you charge to do this for me?
I love the way it turned out...

Tony

where did you get the materials for this?

Is there a web site with a write-up on doing the modifications to the stock intake? I found that you could use a cut off wheel to open it up, or a plasma cutter. There doesn’t seem to be much said in the tread about the neck area modification, but what was done with the connection to the EGR port.

Would love a complete write-up with photos, to do it myself and have some one locally weld it back together. Although I have to many projects, would someone be making a modification service available?

quote Originally posted by DandRauto: Is there a web site with a write-up on doing the modifications to the stock intake? I found that you could use a cut off wheel to open it up, or a plasma cutter. There doesn’t seem to be much said in the tread about the neck area modification, but what was done with the connection to the EGR port. Would love a complete write-up with photos, to do it myself and have some one locally weld it back together. Although I have to many projects, would someone be making a modification service available?

so far - this thread is it. and, it really is a straight forward thing. the pics say it all. cut cut cut - re-weld - done. paint.
the EGR - looks like he was thinking the same thing I am - get rid of it. mine is already disconnected, and it is disabled in the ECM. but, you could leave it - the main restriction is actually after the EGR port. but, the EGR port is a vortex generator - which means restriction. if you wanted to keep it, I would recommend relocating, or at least making it hit at a better angle.

quote Originally posted by Pyrthian: where did you get the materials for this?

answering my own Q:
www.onlinemetals.com
cut & shipped to my door.....yay

Is there any special type of aluminum that is required? Does it makes a difference when welding it?

This in not a structural piece so Aluminum is not crtitcal. I took the preped intake to my local fabrocator. He fit and welded the bottom and neck pieces from stock he had in the shop.. The heat of welding warped the the manifold flanges slightly. I droped it off at the local machiner shop and had the flanges milled flat. I had to reem a few of the bolt holes to line up.

Chuck

well, got my alum, finally - should be cutting it in this weekend.
I do plan on dynoing this too. and, my neighbor across the street went and got a fiero too. I may be able to talk him into dynoing with me, and when we do 2nd runs, swaping the plenums. so, we can see exactly the diff on my built up 3.1 w stock & cut-up, and his stock 2.8 with his stock intake & my cut-up intake.
I'm sure everyone wants to see this.

------------------
1985 Fiero SE - Plain Red V6 Coupe
3.1 Crane272 MSD 4.10-4spd DarthChip Borla
D.A.M.M. - Drunks Against Mad Mothers

well, finally got the neck piece fitted in & welded. boy, that was not easy. the odd angles & unconsistant width made it a real tough job to match a peice to fit. anyways, did much cleaning inside the plenum & did alot to free up the top half of the bend into the runners.

quote Originally posted by Pyrthian: I'm sure everyone wants to see this.

Right on Thanks.

Fierochild:
Approximately what were you charged at the Fabricators to make and weld the bottom back together?
Also what did the charge to mill it for flatness at the machine shop?

Pyrthian;
If you welded this yourself, was it TIG or MIG? And what size?

Thanks

So far mine is all cut up and ready to fab and weld the bottom.

actually, my buddy is welding it - not sure. I'll ask tommarow, going to do more grinding & setup for the main bottom peice.

As best I recall The welding cost me $75.00, and the milling was $50.00 Both were droped off with "Get to it when you have free time." The work was done in the fall which is the slow time for both shops.

The welding was tig. Aluminum is very difficult with mig.

Chuck

PS: It was necessary to machine the top ribbed area in order to have a flat surface to mill from.

[This message has been edited by fierochild (edited 03-21-2007).]

still working on mine. I'm doing it a buddies house, so basicly - its on his schedule. but, all the ports are now fully done & belled out, the neck tube is done, and the top plates are on, so its down to the bottom plate. not quite as pretty as the one Triker did.....

Prythian,

Any updates? (Shamless bump to the top)

well, did some more work tuesday. weren't happy with the welds on the 2 filled in sections, cut them out & re-did. working in my bud's garage, so 1st step is make sure he's available. he's got all the toy's (welder, plasma cutter, etc). then theres the 2nd guy - but, most his work is done - the machining. we should be finishing this weekend (3rd time I've said that...). basicly - just getting the 3 of us together is the main hold-up....

Up up and away...

yup...still not done - but, I did get a spare upper plenum to use in the meantime - so I can drive my car.....
just got done putting that in - and, lucky me - it was gasket matched already. so, I just had to grind out at the neck area for the 57mm throttle body.
basicly - got NOTHING done in april....

yay - finally getting back at it - one of the guys that does the machining broke his ankle, and took him out for awhile - but anyways - back at work - go the bottom plate welded down. so, it is almost done. just need to make the last peice to fill the transition from the neck to the bottom plate.

so, to refresh - basicly doing the same thing as what started this thread. but, did ALOT more porting. the alum around the curve, where the upper & lower plenum come together is mighty thick. I was able to take out over an 1/8" thru that whole curve. in terms of volume, that is ALOT. but, the alum is pretty thin at points, and I did have cracking problems from the thin alum & the welding heat.

so, I am almost to my 6000 shift point & 7000 redline. one more hunk of alum & some grinding.

and, side note - I am starting to collect the goodies for the 7730 ECM converion

welding is DONE. YAY. got it mostly ground down, and using epoxy to fill some tough spots. I was planning on using FiberGlass resin to smooth the insides. but, someone mentioned that the resin is gas soluable. I dunno if this will work now. yes, while running - all the fuel vapor is in the intake manifold, not the plenum - when the car is shut off tho....
what else is runny enough to pour into the neck to fill on the insides? not a huge issue - but, with all the work into it sofar - wanna do it to the max.

Glad to hear you're back on track, please keep us posted

If you are also doing the ECM upgrade are you doing the digital EGR, if so was there anything different with the EGR port on the neck of the intake? Got any new pictures?

tonight is the pressure test. I mounted the upper plenum to a spare lower plenum, with plexiglass between them. hoses with bolts & clamps on all the vacuum ports. and, got a plate, with a airhose jack, to mount on the throttle opening. gonna pump it up to 50 PSI and see if it holds.

got the base painting done, and, did use fiberglass resin to smooth the interior welds as best as I could. getting my "Fiero" sticker to put back on top from Rodney soon. and a tach filter. since my tach has been flakey/jumpy in the upper revs, and with the new intake - I plan some major rev'ing

pics...wish I had pics...it looks sooo good

failed the pressure test. found quite a few pinholes and one good sized hole. went and fixed them up "dentist" style. took a pointy carbide bit, and drilled into each hole, and anything that looks like it maybe a cavity. then mixed up some epoxy, and filled them all in. gonna sand them tonight, and try again.

one of the things that makes me so happy when working on it, is you can see the rear ports thru the neck. open is good.

finally done. painted, and installed.
YAY
looks dang good. really wish I had a digi-cam to post pics along the way.

now, unfortunatly, last week my car started getting a miss in the upper R's....around 4000 - so - now that I can breath up there - I cant seem to make spark no more....grrrr....anyways for another thread....

quote Originally posted by Pyrthian: finally done. painted, and installed. YAY looks dang good. really wish I had a digi-cam to post pics along the way. now, unfortunatly, last week my car started getting a miss in the upper R's....around 4000 - so - now that I can breath up there - I cant seem to make spark no more....grrrr....anyways for another thread....

Would you post your results when your car is back to normal?


Thanks!!!

------------------
Todd,
2006 Pontiac Solstice
2004 Volkswagen Beetle Convertible (Wife's Car)
2002 Ford Crown Victoria LX
1987 Pontiac Fiero SE / V6 (3.2) 5-Speed
1984 Porsche 944 5-Speed
1981 Pontiac TransAm (Olds 455BB)
1973 Volkswagen Type-2 Transporter

quote Originally posted by 82-T/A [At Work]: Would you post your results when your car is back to normal? Thanks!!!

OH YES
I am planning a dyno trip & the results used for a new chip.

------------------
1985 Fiero SE - Plain Red V6 Coupe
3.1 Crane272 MSD 4.10-4spd DarthChip WCF Long Tubes Borla
D.A.M.M. - Drunks Against Mad Mothers

You're high RPM miss is most likely due to running Lean if you are using stock injectors. I went with 19# injectors, and had the opposite problem. Still working on getting the tune right.

Chuck

quote Originally posted by fierochild: You're high RPM miss is most likely due to running Lean if you are using stock injectors. I went with 19# injectors, and had the opposite problem. Still working on getting the tune right. Chuck

this started just before I swapped the manifolds.....and I got 17# injectors
I do have a feeling it maybe a fuel deleivery problem - it is still the original fuel pump - 130k on it.....
but, I am gonna start with ingition - which it mostly feels like.

miss is usually ignition. 4k rpm is nothing for the stock fuel system. it runs rich at high rpms anyway, at least as far as I can see from my plugs. my motor almost daily goes to 6k+ at some point, and I have no issue with fuel with stock injectors. Actually I am more surprised the stock ignition is holding up at 6k, still the original 88 module and coil.

quote Originally posted by tjm4fun: miss is usually ignition. 4k rpm is nothing for the stock fuel system. it runs rich at high rpms anyway, at least as far as I can see from my plugs. my motor almost daily goes to 6k+ at some point, and I have no issue with fuel with stock injectors. Actually I am more surprised the stock ignition is holding up at 6k, still the original 88 module and coil.

Yeah, at 130k, my entire ignition system was pretty much shot. I replaced the coil with an Accell, a new ICM, and I rebuilt the distributor with new bushings (I think), and a new "pickup coil". The wear pattern on the distributor gear was perfect, so I re-used it with my engnie rebuild. I had actually rebuilt it AFTER I rebuilt the motor, and noticed an IMMEDIATE and drastic improvement. The car just felt like an old car with the old distributor components and coils and everything else...

------------------
Todd,
2006 Pontiac Solstice
2004 Volkswagen Beetle Convertible (Wife's Car)
2002 Ford Crown Victoria LX
1987 Pontiac Fiero SE / V6 (3.2) 5-Speed
1984 Porsche 944 5-Speed
1981 Pontiac TransAm (Olds 455BB)
1973 Volkswagen Type-2 Transporter

quote Originally posted by tjm4fun: miss is usually ignition. 4k rpm is nothing for the stock fuel system. it runs rich at high rpms anyway, at least as far as I can see from my plugs. my motor almost daily goes to 6k+ at some point, and I have no issue with fuel with stock injectors. Actually I am more surprised the stock ignition is holding up at 6k, still the original 88 module and coil.

got another thread going on the miss:
https://www.fiero.nl/forum/Forum2/HTML/085175.html

I have a MSD coil & Accell wires. had the MSD 6 box for awhile - but it was not reliable, and didnt do squat.
and, there is still the 7730 ECM w/DIS for this winters project

I also had my dist gear fail recently, and did freshen up the dist. pick up coil, igntion module, cleaned bushing, tweeked them funny 6 prongs & of course cap & rotor.

[This message has been edited by Pyrthian (edited 08-16-2007).]