Homebrew intake lid spacer - 2003-04 Mach 1 Registry Owners Club

Krwy · 05-29-2009, 10:50 PM

I was looking at buying an intake spacer. I didn't want to shell out $xxx for the spacer. I have a full shop at my disposal so I went ahead and made my own. No offense to anyone who makes them, but I'm on a tight budget and couldn't pay that much for something I could make. Its made from polycarbonate plastic. Not worried about temp deformation, can withstand 250* of direct heat before losing its shape.

one mach 1 · 05-29-2009, 11:35 PM

Sweet! Let us know how it melts!

Krwy · 05-29-2009, 11:41 PM

Quote:

Originally Posted by one mach 1

Sweet! Let us know how it melts!

harhar. I made 2 'washers' out of the same material about 2 weeks ago and bolted one to the manifold, and one to the EGR. No change in torque load on the bolts, and no melting. I drove around and used the laser temp gun and took temps off the manifold. Then tested the material with a heat gun, and the material holds up fine until 250* where it gets soft. The highest temp I got from the manifold was 175* after a long drive, and leaving it parked where it would basically 'bake' under the hood.

Plus, what do you think the gasket is made out of? Plastic and rubber.

one mach 1 · 05-29-2009, 11:43 PM

Quote:

Originally Posted by Krwy

harhar. I made 2 'washers' out of the same material about 2 weeks ago and bolted one to the manifold, and one to the EGR. No change in torque load on the bolts, and no melting. I drove around and used the laser temp gun and took temps off the manifold. Then tested the material with a heat gun, and the material holds up fine until 250* where it gets soft. The highest temp I got from the manifold was 175* after a long drive, and leaving it parked where it would basically 'bake' under the hood.

Plus, what do you think the gasket is made out of? Plastic and rubber.

Hmmm. It might be worth trying. Let it sit under your hood for a hot summer and a cold winter before giving it the thumbs up.(Mid west winter, Calif. summer.) otherwise it looks good. Any other materials that will last 1000 winters?

2k4mach · 05-29-2009, 11:46 PM

driving around isnt the same as sitting in stop and go traffice in the 100 degree summer heat. i dunno if id feel comfortable running that where i live.

one mach 1 · 05-29-2009, 11:49 PM

How about a composite material similar to a head gasket?

Krwy · 05-29-2009, 11:50 PM

Quote:

Originally Posted by 2k4mach

driving around isnt the same as sitting in stop and go traffice in the 100 degree summer heat. i dunno if id feel comfortable running that where i live.

Thats the reason why I let it sit under the hood after a long drive and 'bake.' The gasket itself is plastic. This same material is used on conveyor systems that transfer parts in and out of ovens. I picked up the sheet from my buddy who runs the CNC programming for a conveyor systems manufacture here in SoCal.

If I had a plate of aluminum I would have made it out of that. And for an 1/8th of the cost of the same thing, why not?

one mach 1 · 05-30-2009, 12:00 AM

Quote:

Originally Posted by Krwy

Thats the reason why I let it sit under the hood after a long drive and 'bake.' The gasket itself is plastic. This same material is used on conveyor systems that transfer parts in and out of ovens. I picked up the sheet from my buddy who runs the CNC programming for a conveyor systems manufacture here in SoCal.

If I had a plate of aluminum I would have made it out of that. And for an 1/8th of the cost of the same thing, why not?

It is worth a try!

ModularSpeed · 05-30-2009, 12:16 AM

Props!

I once spent almost $300 on a spacer.

I will now use a $20 sheet of phenolic, and make my own.

All you have to do is lay a gasket down, secure it, and trace it. Then proceed to cut along the lines. lol

Roy · 05-31-2009, 04:54 PM

Where can I get phenolic sheet for $20?

Unrealford · 05-31-2009, 04:58 PM

Summary
Polycarbonate plastic is a lightweight, high-performance plastic that possesses a uniquebalance of toughness, dimensional stability, optical clarity, high heat resistance and
excellent electrical resistance. Because of these attributes, polycarbonate is used in a
wide variety of common products including digital media (e.g. CDs, DVDs), electronic
equipment, automobiles, construction glazing, sports safety equipment and medical
devices. The durability, shatter-resistance and heat-resistance of polycarbonate also
make it an ideal choice for tableware as well as reusable bottles and food storage
containers that can be conveniently used in the refrigerator and microwave (APME)

rich1 · 05-31-2009, 06:50 PM

Wait till you start chasing air leaks in the intake .The gasket is held in place by pins and bolts squeezed between alum.

Krwy · 05-31-2009, 09:51 PM

Quote:

Originally Posted by rich1

Wait till you start chasing air leaks in the intake .The gasket is held in place by pins and bolts squeezed between alum.

Why would it leak? This isn't my first rodeo. This being clamped down by all 7 intake manifold bolts, and having the factory gasket on top and bottom there shouldn't be a problem.

rich1 · 05-31-2009, 10:14 PM

Quote:

Originally Posted by Krwy

Why would it leak? This isn't my first rodeo. This being clamped down by all 7 intake manifold bolts, and having the factory gasket on top and bottom there shouldn't be a problem.

Ok ..

Krwy · 05-31-2009, 10:16 PM

No, really I'd like to know? Why would it leak?

rich1 · 05-31-2009, 10:30 PM

Not to start an argument.....but...Being a former Ford Tech ...I will just say that Fords TSB on the Plastic 2v intake replacement cost them plenty . I did not say it would not work its just a question of how long. If it is a question of $ Kar Kraft sold them for $50.Save a dime spend a Dollar.

gregscott · 05-31-2009, 10:30 PM

Some composites and or plastics lose there stability after heating and cooling cycles, keep testing it's called R&D

ModularSpeed · 05-31-2009, 10:53 PM

Quote:

Originally Posted by Roy

Where can I get phenolic sheet for $20?

I use McMaster-Carr for any kind of materials I use. Cheap and fast shipping as well.

The last time I made a few spacers, I paid roughly $24 shipped for 12x24 sheets, IIRC. I order everything I need from them, through my work. I'll check tomorrow and see what kind of prices I can get, as I may be making up a few more for some customers very soon!

Here is the last sheet I have left, just snapped this pic....ready to be cut out.

ModularSpeed · 05-31-2009, 10:59 PM

Looks as if they went up slightly, unless I get a discount.

3/8" Phenolic Sheet
http://www.mcmaster.com/#8525k136/=24dsg3

3/4" Phenolic Sheet
http://www.mcmaster.com/#8525k141/=24dru5

Krwy · 06-01-2009, 12:47 AM

Quote:

Originally Posted by ModularSpeed

Looks as if they went up slightly, unless I get a discount.

3/8" Phenolic Sheet
http://www.mcmaster.com/#8525k136/=24dsg3

3/4" Phenolic Sheet
http://www.mcmaster.com/#8525k141/=24dru5

Wow man, thanks for the link. I might order up the phenolic sheet just to have a spare.

GroverDill · 06-10-2009, 08:34 PM

Pretty cool! I however have no skill, desire, or patience to fab up anything, thus I gladly bought from Roy.

littlemags · 06-10-2009, 09:27 PM

pretty neat...like the idea.

pietell90 · 06-10-2009, 09:39 PM

polycarbonate is some bad ****. i think its gonna be fine great idea either way tho

DanB · 06-10-2009, 10:03 PM

sweet man should work fine

bangingeauckyrs · 06-10-2009, 10:18 PM

they also make some ultra high density, high heat, oil resistant stuff my machinist uses all the time for intake and carb spacers, feels like the stuff used in plastic cutting boards, but high heat.

05-29-2009, 10:50 PM	#1
Krwy Registered User Join Date: Mar 2009 Location: Bellflower, CA Posts: 125	Homebrew intake lid spacer I was looking at buying an intake spacer. I didn't want to shell out $xxx for the spacer. I have a full shop at my disposal so I went ahead and made my own. No offense to anyone who makes them, but I'm on a tight budget and couldn't pay that much for something I could make. Its made from polycarbonate plastic. Not worried about temp deformation, can withstand 250* of direct heat before losing its shape. __________________ '03 Mach 1 UPR o/r x pipe, Magnaflow CB, FRPP 3.90s, SCT X3, Koni D/A shocks and struts, H&R Race Springs, MM PHB. '89 LX Coupe DarkShadowGray H/C/I, built suspension

05-29-2009, 11:35 PM	#2
one mach 1 Pro-gun Conservative! Join Date: Jul 2003 Location: Murrieta Calif. Posts: 3,608	Re: Homebrew intake lid spacer Sweet! Let us know how it melts! __________________ Gear head with 4.56's

05-29-2009, 11:46 PM	#5
2k4mach LuLz Join Date: Dec 2003 Location: Cedar Park, TX Posts: 19,294	Re: Homebrew intake lid spacer driving around isnt the same as sitting in stop and go traffice in the 100 degree summer heat. i dunno if id feel comfortable running that where i live. __________________ 11 Sterling gray GT500 coupe 08 Silver Z06 1058rwhp/1073rwt @ 15psi 14 Silver Q50S Vortech blown 04 DSG Mach 1 (stolen) 03 OW Mach 1 (sitting in a field rotting away)

05-29-2009, 11:49 PM	#6
one mach 1 Pro-gun Conservative! Join Date: Jul 2003 Location: Murrieta Calif. Posts: 3,608	Re: Homebrew intake lid spacer How about a composite material similar to a head gasket? __________________ Gear head with 4.56's

05-30-2009, 12:16 AM	#9
ModularSpeed Mach Underhood Join Date: Jan 2007 Location: FL Posts: 1,677	Re: Homebrew intake lid spacer Props! I once spent almost $300 on a spacer. I will now use a $20 sheet of phenolic, and make my own. All you have to do is lay a gasket down, secure it, and trace it. Then proceed to cut along the lines. lol __________________ Stock 4.6 4V, Cobra Cammed: 11.63@117.84 - N/A T45 / 4.56 / Drag Radials - N/A 4V Video

05-31-2009, 04:54 PM	#10
Roy Registered User Join Date: Jul 2005 Location: S.E. Mich. Posts: 3,446	Re: Homebrew intake lid spacer Where can I get phenolic sheet for $20?

05-31-2009, 04:58 PM	#11
Unrealford Mustang owner since 1984 Join Date: Sep 2003 Location: Buffalo, NY Posts: 4,515	Re: Homebrew intake lid spacer Summary Polycarbonate plastic is a lightweight, high-performance plastic that possesses a uniquebalance of toughness, dimensional stability, optical clarity, high heat resistance and excellent electrical resistance. Because of these attributes, polycarbonate is used in a wide variety of common products including digital media (e.g. CDs, DVDs), electronic equipment, automobiles, construction glazing, sports safety equipment and medical devices. The durability, shatter-resistance and heat-resistance of polycarbonate also make it an ideal choice for tableware as well as reusable bottles and food storage containers that can be conveniently used in the refrigerator and microwave (APME) __________________ 2012 Kona Blue Metallic BOSS MOMS Racing... 11.92@115.43 stock besides drag radials http://www.dragzine.com/news/moms-ra...2013-schedule/

05-31-2009, 06:50 PM	#12
rich1 AUTOMACHTIC Join Date: Oct 2007 Location: RTP/ N.C. Posts: 4,813	Re: Homebrew intake lid spacer Wait till you start chasing air leaks in the intake .The gasket is held in place by pins and bolts squeezed between alum. __________________ UPGRADES...Tokico Illuminas Borla SS Catback , Steeda Underdrives , Strut Brace , HPM Lower K Brace , L /C Arms , U /C Arms , HPM PanHard Bar, K&N FRPK 2, GOODYEAR GT1 , MRT- H-Pipe , JLT VaporTraps , SLP-12'" Tips! , FRPP Shorty 1 5/8 Headers , Brembo D/S & PBR D/S Rotors ,FRPP Alum.DS ,Roys 3/8 Spacer , SVT Focus 255 pump SCTsw Chip PRO-DYNOjet NA 300.01hp /315tq (Auto) ,Innovate W/B ,Compucar Wet Kit (90jet) + Heater and E Gauge * 360 hp/385tq 12.5 -1/4 @112

05-31-2009, 10:16 PM	#15
Krwy Registered User Join Date: Mar 2009 Location: Bellflower, CA Posts: 125	Re: Homebrew intake lid spacer No, really I'd like to know? Why would it leak? __________________ '03 Mach 1 UPR o/r x pipe, Magnaflow CB, FRPP 3.90s, SCT X3, Koni D/A shocks and struts, H&R Race Springs, MM PHB. '89 LX Coupe DarkShadowGray H/C/I, built suspension

05-31-2009, 10:30 PM	#16
rich1 AUTOMACHTIC Join Date: Oct 2007 Location: RTP/ N.C. Posts: 4,813	Re: Homebrew intake lid spacer Not to start an argument.....but...Being a former Ford Tech ...I will just say that Fords TSB on the Plastic 2v intake replacement cost them plenty . I did not say it would not work its just a question of how long. If it is a question of $ Kar Kraft sold them for $50.Save a dime spend a Dollar. __________________ UPGRADES...Tokico Illuminas Borla SS Catback , Steeda Underdrives , Strut Brace , HPM Lower K Brace , L /C Arms , U /C Arms , HPM PanHard Bar, K&N FRPK 2, GOODYEAR GT1 , MRT- H-Pipe , JLT VaporTraps , SLP-12'" Tips! , FRPP Shorty 1 5/8 Headers , Brembo D/S & PBR D/S Rotors ,FRPP Alum.DS ,Roys 3/8 Spacer , SVT Focus 255 pump SCTsw Chip PRO-DYNOjet NA 300.01hp /315tq (Auto) ,Innovate W/B ,Compucar Wet Kit (90jet) + Heater and E Gauge * 360 hp/385tq 12.5 -1/4 @112

05-31-2009, 10:30 PM	#17
gregscott Registered User Join Date: Sep 2005 Location: Boston Posts: 123	Re: Homebrew intake lid spacer Some composites and or plastics lose there stability after heating and cooling cycles, keep testing it's called R&D

05-31-2009, 10:59 PM	#19
ModularSpeed Mach Underhood Join Date: Jan 2007 Location: FL Posts: 1,677	Re: Homebrew intake lid spacer Looks as if they went up slightly, unless I get a discount. 3/8" Phenolic Sheet http://www.mcmaster.com/#8525k136/=24dsg3 3/4" Phenolic Sheet http://www.mcmaster.com/#8525k141/=24dru5 __________________ Stock 4.6 4V, Cobra Cammed: 11.63@117.84 - N/A T45 / 4.56 / Drag Radials - N/A 4V Video

06-10-2009, 08:34 PM	#21
GroverDill Registered User Join Date: Feb 2009 Location: San Diego, CA Posts: 60	Re: Homebrew intake lid spacer Pretty cool! I however have no skill, desire, or patience to fab up anything, thus I gladly bought from Roy.

06-10-2009, 09:27 PM	#22
littlemags finally paid for Join Date: Nov 2004 Location: Ypsilanti Twp, Mi Posts: 4,077	Re: Homebrew intake lid spacer pretty neat...like the idea. __________________ 2004 mach 1-turbo build in progress.. Fast xfi 2.0 OLD combo- 826rwhp/720 trq -100 shot NX 9.13@154 on 100 shot NEW- in progress...

06-10-2009, 09:39 PM	#23
pietell90 Registered User Join Date: Sep 2008 Location: south lyon, mi Posts: 201	Re: Homebrew intake lid spacer polycarbonate is some bad ****. i think its gonna be fine great idea either way tho

06-10-2009, 10:03 PM	#24
DanB 1 man Army Join Date: Apr 2006 Location: Phoenix Posts: 2,955	Re: Homebrew intake lid spacer sweet man should work fine __________________ Dan

06-10-2009, 10:18 PM	#25
bangingeauckyrs Registered User Join Date: Nov 2008 Location: cincinnati ohio Posts: 60	Re: Homebrew intake lid spacer they also make some ultra high density, high heat, oil resistant stuff my machinist uses all the time for intake and carb spacers, feels like the stuff used in plastic cutting boards, but high heat.

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