Figured id post a build thread over here as well, been working on a pretty tricky project for a while now. In my journey to build a almost perfect tribute car and realizing actually finding a production intake manifold is harder than winning the lottery. I have decided build one, yes build, and the cast it out of Carbon 
First step is to build a model, doing so will allow me to build it to fit my needs and since i am using a Australian Boss290 lower intake manifold it will require a custom flange to adapt the two.
I went back and forth on what to use, material wise, to build the model from. In the end i settled on 4lb polyurethane expanding foam. The reason behind this is it is easy to work with, super easy to sand and hand form AND being polyurethane not polystyrene it will handle fiberglass resins easily without having to use exspensive epoxy resins.
Firstly, i had to build a fixture to pour my foam into. I needed a giant block to carve!
The pour foam liquid alone was $100, and i had another $40 or so in materials to build the fixture
First step is to build a model, doing so will allow me to build it to fit my needs and since i am using a Australian Boss290 lower intake manifold it will require a custom flange to adapt the two.
I went back and forth on what to use, material wise, to build the model from. In the end i settled on 4lb polyurethane expanding foam. The reason behind this is it is easy to work with, super easy to sand and hand form AND being polyurethane not polystyrene it will handle fiberglass resins easily without having to use exspensive epoxy resins.
Firstly, i had to build a fixture to pour my foam into. I needed a giant block to carve!
The pour foam liquid alone was $100, and i had another $40 or so in materials to build the fixture
