OBD1 and 2 vr6 2.9 Clone DIY

[WnxGTI]

This is a small DIY on how to create the 2.9 clone intake manifold for the obd1 and obd2 vr6 engines.

This guide will take you from the stock intake (pictured on the left) to the 2.9 clone (pictured on the right)
http://img.photobucket.com/albums/v475/wnxkrayzie/install_007sized.jpg

Safety is always important, there will be sharp bits of metal undoubtedly flying everywhere, including at your face so make sure to get some nice safety glasses, and mechanics gloves don't hurt either.
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1519.jpg

First you need to gut your manifold from the under side. I had a vertical mill at my disposal for this, but with a bit of elbow grease you can use an angle grinder and get the same results.

Now I made a jig (pictured below) to hold my manifold so it wouldnt move around and I knew the top was flat in relation to the work surface.
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1515.jpg

Clamp it in the mill and were ready to start!
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1518.jpg

Using the 1/2" end mill bit I make passes to eliminate the unnecessary metal underneath.
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1520.jpg
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1521.jpg
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1526.jpg

Next your going to need to smooth out the underside of the top plate. I used an angle grinder with a flap wheel and a die grinder with a right angle disc on it.
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1535.jpg
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1546.jpg

Now its time to put a new skin on that beast. I used 1/8" sheet, you may be able to get away with something thinner, but why chance it right? Make sure your surfaces are nice and clean, lay down your sheet and lay that bead. I dont have any pics of the sheet I made but here is the end result.
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1538.jpg
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1541.jpg
http://img.photobucket.com/albums/v475/wnxkrayzie/IMG_1590.jpg

[Die Frau]

Nicely done.

[megafr0]

Does the 2.9 Mani flow better then the stock? Stock VR6's are 2.8L right?

[megafr0]

sam you look so cute in that picture!

[WnxGTI]

From a flow perspective, no the 2.9 clone has no advantages over the 2.8 manifold, if you were to draw a straight line from the outer edges of the intake side to the outer edges of the runners, that is pretty much the lines that the 2.8 mani follows, the 2.9 clone offers a different sound for sure tho.

[megafr0]

I figured that was the case. From what I've heard, the VR6's are already engineered to have maximum flow, interesting that it'd make a different sound.

Could you manufacture something for my 24v VR6? :-)