The start of my new upper intake manifold.
You can quite easily see the side which I have started working on.

One Section of the finished upper,  the plenum will be welded to this one piece at a
time and the ports will be blended into the plenum floor
Al shavings anyone?

Now only a half a million hours work left to make the lower intake move some air,
Lucky for me I love this stuff.

Getting ready to rough in the lower manifold inlet ports

 Rough-in was performed on the mill in an attempt to reduce the amount of work with the carbide cutter.
 

Trever takes a break from porting 460 heads and examines my handy work.

 A little bit of hand blending and a trip to the glass beader and the lower is beginning to take shape.

 IT MATCHES!!!!!!!

And it only took two nights work.

 Now the rest of the port needs some attention.
I'll get to that next.
 

 I think that these shots give a pretty clear idea of what I did to port match this lower intake.

 I was able to step my way down into the port, my biggest concern was the side walls,
they had to have the largest amount of material removed from them.

 Here is a before and after shot of the rough-in process.
 

Fixturing it up on the mill wasn't easy, but it sure saved time in the long run,
I also like the fact that the port walls are parallel to each other.

 A little work with a 6" carbide cutter, a couple of sanding rolls and,

It's Finally Finished!!!

Unfortunately due to time constraints on finishing this project, I did not
have time to put it on the flow bench and get some flow #'s.
It will be flowed and tweaked later this year after end of the season when the motor comes apart again.