You can do it. Eat the elephant one bite at a time and work at it....you'll get there, and it's a place worth getting to. Best, Kelly

That message is a big part of the purpose of my channel, that being it can be done, but will take some commitment. Thanks for watching. Best, Kelly

The FE intake design was done to meet the racing rules back in the late 50's to early 60's . Basically if the cast iron intake was to be replaced with a lighter material intake (aluminum) the Ford engineers wanted to maximize the size of the replacement so 25% or so of a head was part of the intake manifold.

@@JD-fx1mb I didn't know that. Pretty big impact on the guys with wrenches though. Best, Kelly

Ahh, high praise from my sensei! You went above and beyond the call providing learning support to me my friend. -So much appreciated! For those looking to develop your CAD skills, Konstantinos is a CAD virtuoso. Check out his channel @ExMachinaEngineering and support him on the TooTallTony leader board. Best, Kelly

​​@@kellycoffield533I think you just made me look good as a teacher because you wanted and could learn. I gave you a direction but you ran the distance. All of the runner design, parting line, and split models, and CAM specific models you did completely on your own after all.

It did take me a while to figure out the CAD modeling techniques but was well worth it. This intake was purpose built to fit the FE Power FE intake adapter but there will be a 351c and Boss 032 version with integral valley pan. Thanks fr watching. Best, Kelly

Ya never know....😇 Best, Kelly

Not afraid to spend but more weighted on time and effort. Best, Kelly

Clevelands Forever!

Glad it was helpful. The primary message of the channel is lost foam is a practcial method for hobbyists to make larger quality castings at home. It'll take more effort than watching one video, but certainly can be done and is a place worth getting to. Best, Kelly

I've worked very hard at that and there is not a simple answer. I believe it's a combination of a number of things. Part design, feed system design, pouring cup design, and coating permeability. Most of my parts are relatively thin walled and have lots of surface area compared to their volume. This along with the permeability of the refractory coating means the evaporating pattern gases vent very well to the mold. The sprue and gating system design using low density foam with high pattern contact area and sprue height produce good head pressure and generous area to more uniformly feed the part, and lastly the shape and depth of the pouring cup help prevent turbulence, immediately covering the sprue with 4" of molten metal establishing a tranquil and orderly fill of the mold. On the latter, many people allow the sprue to protrude well above the sand surface in a round can. That exposed sprue immediately ignites and floats beacuse it is exposed to air and usually wreaks havoc in the cup as more metal is poured on top of the burning polystyrene fuel whereas my pouring cups sit flush on top of the sprue. I was amazed how much cup shape seemed to help. Round cans/cups and sprues tend to aspirate air due to coriolis affcet, whereas square offset cups and square sprues do not. Best, Kelly

@@kellycoffield533 Wow! Thank you very much for the very detailed answer and taking the time to reply. Awe inspiring work!

Casting Call? I like that one.....think I'll borrow it 😀 Best, Kelly

The greatest intakes never made.... 😁 Best, Kelly

Were the titanium valves a Ford part number ?

@@jesse75 Yes. They were genuine Ford off-highway parts

@@jesse75 I still actually have one exhaust valve from that engine. The bottom face of it is also dished, rather than flat like the stock unit. The stem is straight cut down to valve head, rather than having that thickened portion rear the head like stock has. They are MUCH lighter. They were available from Ford's "Off-Highway" parts manual back at the time, which I also still have.

@@FiteTheGoodFight thanks for the answer. One reason I asked is a couple years ago I bought a vintage built race car. The car is a 67 fastback mustang. Race modified. The engine is a 1964 427. As soon as I got the engine home, I pulled it and took it apart. The valves were 2.19's titanium intakes. On the side of the stems there's a Ford oval stamped or engraved or printed on them. The exhaust is also marked. They were the 3/8 stems and not the 11/32's. Did you ever see the valves out of the 302 and were they marked ? You can see and hear the engine running on a utube video I put up at : " 427 FE with a new set of valve springs " I'm trying to trace and figure out all the parts in the engine and try to figure an exact time frame when the engine was built.

@@jesse75 Interesting. No, the valve I have here was swirl polished, so no ford logo on it. I only have my dad's testimony that it was a ford part. It is the 11/32" stem.

Well not exactly, but yes for the Inline Carb stuff. www.inlinecarb.com. I'll be doing a major rework of this website in the near future and these systems will be available there. I'm an admin at www.TheHomeFoundry.org. You can become a forum member for free casting advice and community support there. Thanks for watching. Best, Kelly

Your forum never sent me confirmation mail

@@farhanchoudhre6962 Let me know the user ID you intend to use and I will watch for you. Sometimes IP addresses get flagged due to other activity and that can result in a rejection. Best, Kelly

Commercial roofing contractors use thick XPS. You need to ask about the product and density. The high compressive strength stuff mechanical contractors use under concrete can be too dense but the roofers use lower density board. Flotation billets are also too dense. Best, Kelly

Thank you Kelly!!!

I use CAMOTICs g-code simulation software to prove out the CamBam CAM programs before I cut patterns. It can be downloaded for free (search it). The MillRight CNC router controller is GRBL based which is also open source. I use the GRBL post processor that was provided with CamBam CAM software with a mod to how it reads and executes arcs. That mod was done by a CamBam forum member for me. Ever since then CamBam spits gcode that works flawlessly every time. Best, Kelly

For the center spyder section it was about 90 minutes/side x4 (two side for two pieces). I really didnt make any effort to optimize the run time. Just set up flipped the switch and went and did something product. With work it could probaby be half that but doesnt make much sense to invest the time when you're only making a couple pieces. Best, Kelly

No book, but kind of a lessons learned thread. forums.thehomefoundry.org/index.php?threads/confessions-of-a-lost-foam-caster-5-years-on.1650/ It's a little dated and needs an update. You will need to join the forum to see full size pictures. Best, Kelly

I suspect everything looks nice sitting atop a 427 in a '68 Stang 😀. Best, Kelly

I pulled a silicone mold from an existing part, then melted and poured wax using is it as an open face mold, strinking off the surface with a razor blade. When cooled, I gently flex the mold and extract with a pick and tweezers. Then apply white PVA glue with a tooth pick and hand place the applique on the pattern. Best, Kelly

101.3%. In other words, .013 units/unit. Best, Kelly

Watch these videos: kzfaq.info/get/bejne/iph4a7h5mLrJkYE.html kzfaq.info/get/bejne/gsqXes6i29GZnZc.html Surf my channel for more.

@@kellycoffield533 Thank you sir

A356 Aluminum Ingot. Best, Kelly

Fantastic. Can You give me your email address please?

One of my friends takes all my used pistons from engine rebuilds and melts them down to make parts for cabinets and wood work.

Hopefully you find the channel helpful and useful. Plastic sheet would be melted by the hot sand in a split second. It will also melt the thread that binds the soles to your shoes 😉 I resue it many, many, times but at $20/ton it's not much of a concern. Best, Kelly

@@kellycoffield533 Good point, - maybe some sheet metal shaped like a tray, with a spout at one end/corner for pouring it back into the container? There was a bit more I added to the initial post, too. Dang, that's cheap, I love the prices you chaps have over there.

@@gordowg1wg145 I have a large drip tray from my automotive lift I use when the pavement is wet. Best, Kelly

I increase the model size 1.3% for shrinkage (global rescale to 101.3%). It's the very last thing I do in my CAM program before I cut the patterns. I could do it in either my CAD or CAM software but I prefer to work in the native dimensions which are more recognizable to me. Best, Kelly

Previously had access to CFD software but no longer do. Have crude orifice plate flow bench. Best, Kelly

No. I sanded those surfaces on the pattern before I cast them so the as cast finish is quite good compared to most commercial castings. Best, Kelly

I do have a model of a Ford 427 SOHC Cammer.....but have a lot of other projects on the go. Some day maybe. Best, Kelly

I think it's called suspendaslurry or similar.

Not out of the question....but not next. Best, Kelly

8.7" deck? No. But I do have Windsor options available in 8.2 and 9.2 deck depending upon your cylinder head and port location. They are based on Trickflow EFI lower manifolds with a custom plenum and carb adapter. As far as just the intake manifold casting goes, they can be quite a bit more economical than a full custom casting depending upon how you want it finished. Ifthat's of interest you can contact me through www.inlinecarb.com or at the forums.thehomefoundry.org/index.php forum. Best, Kelly

@@kellycoffield533 My bad I hit the wrong key sitting here in the dark. When you're over 70 the eyes don't work so good.

Sorry, I dont understand "EVA".

@@kellycoffield533 better, do you use xps foam in your projects? Thank you

@@cncbrasil3507 Yes, XPS, EXtruded PolyStyrene insulation board. 1.3-1.5lb/ft3 density. Best, Kelly

Don't know how you can say without knowing the engine spec and intended duty. I think it's about right for the typical customer. FWIW, it has as much or more plenum volume than any aftermarket single plane open plenum conventional four barrel intake, and in any case, is easily changed with spacer between the intake and lid, asis the distance from the throttle plate to the plenum port windows, which is why it was designed as it was. Best, Kelly

At 875 cfm, it's big for a flatty. Best, Kelly

SEarch my channel "Refractory Coatings". There is a video dedicated to the subject. Best, Kelly

@@kellycoffield533 thank you!!