As many of you know, bought an HSR from EBay. Here it is:

I got it today at 1:00 and i drove it down to the machine shop. They quoted me $800.00, I RAN. On the way home I decided to do what I had been planning all along. I worked on it from 4:12-8:15. Here's what I ended up with:


The plan was to do what JOBY did (!Thanks Joby!). I noticed that the back was sitting on the top of the fuel rail mounts and the front was to be 8.6 inches from the china wall.
I started by marking out the perimeter of the intake onto the plenum. The plan was to cut on the outside edge of the markings to give me room to work, I knew I would have to go further. I thought about using my grinder but if anyone of you read my previous post you know my compressor won't keep up. I'm glad i didn't.
Here's what i did:

Jig saws do not like to cut around corners. I pie cut to the edge of the line with a jigsaw and a metal blade. The jig saw worked great. At times the teeth on the blade would get caked with aluminum. You could tell right away because it would stop cutting. I would simply take a screwdriver and scrape the aluminum off the teeth and keep working.



I couldn't get around the bolt towers with a jigsaw. I took my drill and an 8mm drill bit and drilled 3 holes around the perimeter. Then I wallowed it out until they met. With the dremel and a cutting wheel I cut the bottom of the towers out.



I couldn't use my grinder so I had to find another way. This is what i ended up with, a dremel with a router attachment and an aluminum grinding bit. It was perfect for the task. I was able to adjust it to a certain height and with the help of lubricant it would slice through the aluminum like butter. After 4 hours my HSR was done. All i need to do is find someone to weld it together.

 

cool beans!

 

I used your line
I can't belive I did it so quickly
It was thanks to Joby and his very well documented mod. I ended up with 9 3/4 at the rear and 8 5/8 at the front. Should clear very well I'm going to ck it out in the morning.

 

I know the end result is that the intake on the base ends up being stuck up inside the plenum. From previous post an pictures it appears that it is close the the top of the plenum. My concern would be does this effect air flow to the runners at the front of the plenum? Has anyone thought of building a plenum out of sheet aluminum where you could increase the volumn to the sides above the fuel rails, maybe keep it the same height over the intake runners, which would at least provide the same volumn and clearance for both the front and back runners?

You could even cut some of the runner down on the sides facing the widened plenum to help cut down on restrictions.

Just an idea.

 

I've thought of doing this and might in the future

 

I can't believe a machine shop wanted $800 to do that mod.

 

He said it would take 7-8 hrs and 2.5 HRs worth of welding
that means they charge 80 per HR

I did it with a dremel and a jig saw in half that time.
Maybe I can silicone it together in 30 minutes

 

This morning I put in in place with the gaskets underneath.
I took some play dough rolled it up and used it for a gauge.
I have 3/4 of an inch in front and 7/8 at the rear.
Front

Rear


The pictures are not that great, sorry.

 

I spent a couple of hours porting it. Total time spent is now 6 Hrs.
now i just need to polish the intake.

 

just a heads up,, bolt on the throttle body and check clearance with the TB on

also, look into a nitrous TB space to move the TB forward so the TB blades don't open up above the #1 & #2 intake ports....

 

Thanks , Im going to order a miniram water neck and a TB spacer. I am also going to grind the coolant outlet off. I can't go without IAC.

 

It was welded this morning. I ordered some fittings for the lines.
I also found a water neck at the parts store that will work.

Don't laugh at the paint im just playing with colors.

 

I was able to get a really good deal on a small cap dizzy and connectors.. almost there



Here is a wiring diagram for those of you who want to try this

 

I wish I had seen this post earlier, I would have hooked you up on the mod and welding. Easy stuff at my house...

 

You are a good guy Aaron, Thanks

 

That is down right awsome! I admire your "No Fear" attitude. I wish I had the time and $$ to do something like this!

 

I owe it to Joby and LD85 without their well documented mods I would never have taken this on.
I'm glad I did

 

 

Ok, it's painted with VHT aluminum and clear
now I just need to bake it and put it on

 

That looks great!! Be sure and let us know how it performs