Does anyone know a shop that can modify/alter an intake manifold.

This is my issue. I picked up an intake manifold for an 02 2.4 cavalier. I also picked up a Cobalt 2.2L intake manifold flange from GMPP. My plan is to get a shop to cut off the 2.4L flange off of the new intake manifold and weld on the 2.2L intake manifold flange. Also i would need to have a few more ports welded in that would allow the factory vacum lines to be re-connected to the new intake manifold.

Thanks for any help that is provided

 

Why not get the correct manifold?

 

they dont make one for my car. ive looked. venom use to make one but they discontinued it in 04 and i have yet to find a supplyer that has one in stock.

and this is a must so i can get rid of my factory plastic intake manifold so i can boost over 7psi

 

Ok, that's a good reason, I was just a little curious. Are there any other GM family cars with non-plastic manifolds that you can use, Sky/Solstice, other Saturns, Pontiacs, Chevys, etc??

Welding a new flange on a cast manifold is always fun, that's for sure. There are a few people on here that should be able to help you with this, and you'll have to take it to a machine shop after that to have the flange flycut for flatness. If you can find a shop with a welder you can trust, that would work also..

There is a really good machine shop close to the gates of Langley, they do great work and do a lot of contract work for Langley. They do great TIG welding also. Can't remember the name of the place though, we occasionally farmed stuff out to them and I assume still do (but I don't work at the same place anymore)..

Just get this:

PN# 88958629
FABRICATED ALUMINUM IN-MANI
Accepts 75mm LS-1 T-Body

It's only around $1000

 

im not looking to get a larger throtle body. esp since the LS1 tbody is cable driven. my tbody is digital.

the manifold i bought is stainless steel along with the flange from GMPP, it also comes pre machined. all i have to do is get it welded to the intake manifold i bought. the 02 2.4l cavy has their runners in the exact same location as my 2.2 engine. that is pretty much the reason why i picked this one. if only venom wouldnt have discontinued the intake mani i would be fine. lol.

i know the Saab 2.0T intake manifold will bolt right up to my car but the tbody flange will need to be machined to accept my tbody.

not sure about the solstice gxp or the sky redline. i know the non gxp and the non redline have plastic intake mani's. allong with the the SS 2.4L non supercharged cobalts.

GM pretty much switch all their small car engines to plastic mani's unless they are forced induction.

oh and the $1,000 thing is no problem. i still ahve 22,000 left to spend on finishing up this car and getting it ready.

 

That's because a plastic manifold will keep the air cooler, provide smoother flow and transitions, more even flow, make more power, and meet emissions better, on a N/A car. Same would be true for a Turbo, if it didn't have issues with the pressure.....

Most good fabrication/machine shops will be able to do the job. Some would be more trusted than others. Go around, ask for a price, and find out who you feel comfortable in having do the work. (Probably the guy who bitches the most about having to do it, because it's a cast piece, and cast stuff sucks.....But.....)

 

^ thanks. i was pretty sure thats what i was going to have to do but i didnt know if anyone new a good one to recomend me to or not.

since the only people i trust are the HT's on my ship. (they did the welding for the bonge on my header for the wideband O2 sensor, did a good job too)

 

I'd still be prepared to get the flange surfaced after machining. Just keep that in mind.

This is just my opinion, but if you have $22k left to spend on this car, why didn't you start with a different car?

 

I agree with this, 100 %. The heat from welding the flange to the IM, will cause the surface to warp and distort. Perhaps it won't be enough to cause a problem with the gasket you use, perhaps it will. It's best to have it finish machined when you're finished! Especially as it will likely only cost a few $$....

 

And you have a 0.55" flange to start with, so you can lose a few thou during surfacing and still have a massively overbuilt flange.