Fabricating the B16-AE101 manifold.
To mate up the AE101 bodies to the B series engine, I decided to make a manifold using the stock mounting flange cut from a spare B16A2 intake manifold - B16A2 because the port does not narrow before the injector pocket and more suited to this job. The difference is only around 1-2mm, but it makes all the difference.
A collection of flanges after being media blasted - you
can see how excellent the finish is. The top flange is
waiting to be trimmed, and the bottom flange is from a D
series DOHC engine for no reason other than I blasted it
at the same time.
The flange has now been machined at an angle, and cleaned.
A flange for the AE101 bodies was cut from 12mm aluminium
plate, and machined to accept the bodies. I had to mill a
few slots to clear the throttle linkages. These were drilled
at 51mm to accept the 2" OD tubing I decided to use for the
runners.
The machined components ready to be test fitted.
The components were then test fitted with a spare head
to check for clearance against the firewall, and to work out
how much room I had spare for a intake horns filter/airbox.
The tubes have now been cut to the approximate length
and the flange has been drilled & tapped for the
throttle bodies. The air horns and filter can now be
ordered.
The tubes have also been finished with a flap wheel, the
whole setup is now ready for welding. The welding will be
performed by an engineering shop as I only have access to an
180amp TIG, which is too lightweight for the thick 12mm
flange.