Coming soon...

You tease!!

Just wanted to include the original discussions over in "General BS"...

http://www.pilotodyssey.com/PO/viewtopic.php?f=2&t=13983

No updates. I have a call with one of the machine shop owners this morning to go over some questions about the print. Stay tuned...

Met with shop #1 yesterday afternoon to debrief on the FL350 manifold and get the next design in motion. Good people.

Preview...

While these are being quoted by the machinists, I'm also looking into investment casting both locally and afar. The "tunnel" on this manifold may not be as "machine-able" as the 350 intake was.

Update on the investment casting avenue...

The cast materials available locally here have a lower tensile strength than the 6061-T6 temper bar stock, about 8-10% lower. But the finish would be baby-butt smooth (so as the master is that smooth), but I also feel the finish on the machined parts is pretty nice. Still requires secondary machining though. Up front tooling cost might be the killer, too, since this is generally suited for higher volume parts versus the "few dozen" we're talking about here. The machine shop just has to chuck up the part in the vice & already existing fixture -- no tooling to pay for. We'll see what the numbers come back as anyways, just to see and to 'check the box'.

As expected, the up-front one-time tooling cost required for investment casting is too high of a hurdle to leap with a part that just doesn't have enough demand. In order to match the cost of cnc'd parts, I'd have to figure out how to sell 150+ intakes. Hence, investment casting for this part would not be a good "investment" (haaaa).

Soooo is this project dead in the water?

This project is 100% alive & well!

In fact, I just got some numbers in this afternoon from machine shop 'A'. Sent them some questions though. Can't release any pricing info yet, but I can confirm there will be a $14-$16 up-charge (each) for 7075 aluminum instead of 6061. In addition to simple higher material price, the 7075 isn't available in as many stock sizes, so there is more waste with the closest available size. Also, lead-time is likely to be ~2-4 weeks after I cut them a big price-is-right check.

In any case, I'm hoping to have parts in hand in time for anyone's Memorial Day buggy excursions.

I'm trying to find a good reliable source and part numbers for the rubber carb flanges with bolt spacing of 74.6mm. I've found some as cheap as $9 shipped in 30-40mm sizes. If I can find good avenues for those boots for people to buy, I will change the Pilot manifold to have only (1) pair of holes. It may also knock a couple $'s off the manifold cost (less features = less machine time = less cost).

Likely the Pilot manifold will cost a few $'s more simply because it uses more material & because the flow port geometry is a little more complicated than the FL350 manny. HENCE, if I can cut some cost out of the total package, we all win!

Sounds good Dmoney!

MORE DESIGN DETAILS...
- The Pilot manifold will have a 39mm diameter inlet hole.
- The 39mm inlet hole has 1.85in2 area
- The outlet hole will match the existing stock Pilot intake/reed geometry
- The outlet 'oval' has 1.88in2 area (slightly bigger than inlet)
- The flow port is very non-disruptive to airflow since it has a cone shape and because the area change is very slight.

Design will stay with the 70mm & 60mm hole spacing.

Prices for the FL400R intake manifold that accepts Mikuni 60/70mm flanges:

In 6061/T6: $116.00, shipped to the lower US48

In 7075/T651: $134.00, shipped to the lower US48*
*7075 material is available via pre-order only
*7075 material will not be available on eBay

Rubber flange is not included.

Lead-time is 2-4 weeks, but first part in 6061 could be available in 4-5 days.

If any are left, evilBay prices will be +$20.

I won't be able to make these prices happen unless I've got at least a total of 15 units pre-ordered. Last count, I had 10 requested from PO.com'ers, but I will need to know which material you want, plus confirm your order. Please PM me.
busdriver x1
pilot bird x4
DC x2
cruz01 x2
rppjr x1



Some information about the 6061 & 7075 aluminum (you'll quickly discover you get a pretty good bang for your 16-bucks with 7075):

T651 temper 7075 has an ultimate tensile strength of at least 67,000–78,000 psi (462–538 MPa) and yield strength of 54,000–67,000 psi (372–462 MPa). It has a failure elongation of 3–9%. The 51 suffix has no bearing on the heat treatment but denotes that the material is stress relieved by controlled stretching. Not recommended for anodizing.

T6 temper 6061 has an ultimate tensile strength of at least 42,000 psi (300 MPa) and yield strength of at least 35,000 psi (241 MPa). More typical values are 45,000 psi (310 MPa) and 40,000 psi (275 MPa), respectively.[4] In thicknesses of 0.250 inch (6.35 mm) or less, it has elongation of 8% or more; in thicker sections, it has elongation of 10%.

I'll go for the 6061 material for both manifolds. Since I'm using a PWK 39mm where do I go to get the flange?

I have the same question?

The best deal I've seen yet >>> Randy J. has found the M-VM36-200 flange over on powersportsuperstore.com for around $14.24 + $2/$3 shipping, and they also carry the M-VM34-200 for the 32-34mm carbs. They're out of TX. You have to search for the part numbers and then add the items to your cart to see the price. Site is a little lacking, but I know Randy got his part.



I paid $20 each for mine off evilBay. The pictures in the auction showed an OE-style clamp, but both arrived with worm-gear clamps. Plenty of them on evilBay & Amazon, but the best price is what I mentioned above.

Otherwise, just search for the Mikuni part numbers. Like I mentioned in the FL350 intake thread, make sure the flange is indeed the M-VMXX-200 part with 60mm (2-3/8") or 70mm (2-3/4") hole spacing.

For the M-VM36-200 part, I believe two alias part numbers are Harley's HS40-K, and Sudco's 002-054. However, I have not confirmed.

And for the life of me, I cannot tell what the difference is between the Mikuni I-series flanges and the M-series flanges. There is an I-VM34-200 as well as an I-VM36-200, but I cannot find them in any Mikuni reference table.

I have bought my CR500 rods from them in the past they had the best prices never any problems doing business with them http://www.powersportsuperstore.com/Pro ... lick=35177

The FL400 intake manifolds have been ordered. Please see the "For Sale" thread for payment instructions and any further details about the part.

Per the 'For Sale' thread, these are all sold out.

To order more, I would need at least (8) pre-orders since the minimum order qty from the machine shop is (10), and I'd keep (2) extra to evilBay. BUT they'd cost $15 more since the previous pricing was based on an order qty of (25) intakes from the shop.

If you are interested in a Pilot intake, PM me, and I can start accumulating interest.

Or if you really really want a Dan-i-Fold for your Pilot and won't be running a stock carb, I don't see why you couldn't run the FL350R intake and then simply adjust the floats to make-up for the 6-deg less angle. The FL350 intake has a 21-deg angle, while the FL400R intake has a 27-deg angle. The carb offset and 6-bolt cylinder pattern is the same for both. The only other difference is the outlet geometry. Take a gander at the FL350R intake thread.


Thanks!

Dan A.

Hi, are these still available?

Hi there and welcome new guy.
I believe DMoneyAllstar sold his last run to someone on this site but I don't remember who. Don't think he is making anymore.
What ever you do don't buy the one from a company we call aftersucks. That unit has serious issues and you may blow your Engine so don't waste your money. It does not seal correctly.
Not sure how mechanically inclined you are but you can make your own like I did here: viewtopic.php?f=1&t=17228

Hi, I have several here I would part with from Dmoney, which one are you in need of!

Mudbogger pm me prices

I would be interested in a price as well if you have any left
Bob