tooter's manifold adventure... - Toyota Yaris Forums

tooter · 06-18-2012, 11:14 AM

Just mill the vertical surfaces and Dremel the angle yourself!

The aluminium is soft. I had already been practicing on the old flange and using a good bit, the stuff peels off smooth like cold butter. Make the outer holes smaller and then feather them out to meet the inner edge of the outer Yaris ports.

Heck, when I first started out I was going to do the whole thing by hand with a drill press and a Dremel!

I was just going to trace the Yaris gasket on one side of a 25mm slab and draw around the Corolla runners on the other side. Then use a drill press to punch out all of the vertically matching areas that go all the way through and Dremel the rest.

Oh, the guys let me in on another tip...
The 25mm bars we're getting have manufacturing rolling/extruding stresses in them and can warp under the heat of welding. So they're going to mill both sides flat and true to remove the more highly stressed and compressed metal at the surfaces. Then they'll lay flat under welding heat.

Any other ideas that are related to me I'll share them with you.

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06-18-2012, 11:14 AM	#11
tooter play every day Drives: 2012 Yaris L 2dr 5sp Join Date: Apr 2012 Location: Los Angeles Posts: 1,961	Just mill the vertical surfaces and Dremel the angle yourself! The aluminium is soft. I had already been practicing on the old flange and using a good bit, the stuff peels off smooth like cold butter. Make the outer holes smaller and then feather them out to meet the inner edge of the outer Yaris ports. Heck, when I first started out I was going to do the whole thing by hand with a drill press and a Dremel! I was just going to trace the Yaris gasket on one side of a 25mm slab and draw around the Corolla runners on the other side. Then use a drill press to punch out all of the vertically matching areas that go all the way through and Dremel the rest. Oh, the guys let me in on another tip... The 25mm bars we're getting have manufacturing rolling/extruding stresses in them and can warp under the heat of welding. So they're going to mill both sides flat and true to remove the more highly stressed and compressed metal at the surfaces. Then they'll lay flat under welding heat. Any other ideas that are related to me I'll share them with you.