(I thoght i'd post this in this section for all the 335er's)
I bought a spare manifold to go on my car whilst i work on my port matched manifold/TB so i can still use the car.
Swapping the manifold/injectors/fuel rail/TB/etc isn't straight forward on my car because the servo is to close to the manifold so you can't pull it of the head studs
So undo the master cylinder and pull it forward, glove box out and undo the servo bolts, pull the servo out the way and the rest of the job was straight forward. It took me about 3 or so hours at a fairly relaxed pace to swap all the parts over.
Lets get busy with the angle grinder, no going back now !
This is the first rough cut hole which was care fully enlarged to fit the adapter plate later on.
In side the manifold.
The inside edges of the hole i cut were chamfered/rounded off so the air doesn't have any sharp edges/angles to obstruct it's flow in side the plenum.
The mating face on the manifold i thought was fairly flat has a nice curve
So cut the long sides of the hole in the manifold so that the adapter plate only sit's on top of the manifold on the short sides and the long sides sit "in" the hole.before..........
and after...........
This is the face of the adapter plate that is in side the plenum, so the air doesn't have to go around a nasty 90 degree edge as it enters the plenum i rounded the edge's of the two holes with a file.
One down one to go, oh i had so much fun with the file
Off to the engineering shop who can TIG weld cast alloy.
Original TB hole blanked of
Adapter plate welded on and new TB bolted on, they look like nice tidy welds that should be air tight once painted(incase theres any tiny pin holes ?)
They also drilled a hole in this spare piece of 20mm alloy for me because i didn't have a big enough drill bit. This piece of alloy is going to house the TPS adapter the Alex kindly made for me as the Ford TB has a flat blade type TPS spindle and i need the normal "D" TPS spindle.
Things to do.........
Make a card board gasket for the TB
Cross my fingers that i can use my old throttle cable and make a new bracket
fit M30 air box and cross my fingers that the E46 M3 intake elows/elbow that Ian is kindly giving me will fit both the TB and the air box
paint manifold and re-fit
Which leeds me on to my manifold cosmectics question, i will be using the same textured/wrinkle effect black paint that i have used on my rocker cover as the texture will help to hide any rough areas on the manifold like the grinding marks i caused when i cleaned the metal up so it was ready to weld.
The question is should i bother grinding smooth the TIG welds and i was also thinking of grinding off the casting seems of the manifold to sort of tidy it up if you know what i mean ?
I also could grind off the old throttle cable bracket mount ?
What do you think ?
