First piece....see pics. Should have them all Wednesday.

Also, the big order of rubber flanges has shipped.

Making a couple of minor changes to the part after playing around with it over the weekend.

Change #1: Targeting a 38.6mm inlet port diameter to ensure the small rubber flange's seal ring still seals. The ID of the seal ring is 40mm. Prior to the change, misalignment of the flange could cause the seal bead to miss. Granted, the flanges still seal just fine. I didn't want to worry about. Those running the 39mm carbs, you aren't missing much. Those running the 32-34mm carbs, you won't have to worry about sealing. =)

39.0mm ID = 4778.3 mm2 flow area
38.6mm ID = 4680.9 mm2 flow area (2% less)

Note: stock 34.0mm carb = 3631.6 mm2 flow area

Most "39mm" carbs generally have an ID slightly less than the nominal.

And...for those anxious to regain that 2% flow area, it would take mere seconds of filing to remove 0.2mm off each side.


Change #2: Trying to get 10% deeper threaded holes. Its fine as it is, but I don't want to leave any thread engagement on the table. With a coarse thread, every thread counts.

I'm hoping the shop can re-program and still have parts ready tomorrow.

The flanges are expected to be here by end of day Thursday, so kits will likely ship out Friday. Flanges left Texas this morning at 10am EST.

Also, I will try to ship parts out the "next day" from when I get them. I've got all the shipping materials, bolts, and addresses all set to go.

-D$

Its looking really good thanks for taking the time to teak things out and not just saying 'close enough' and running a batch.

Does it cost any more to engrave "Made In The USA" on top where its easy to see?

Yep, engraving would cost more (machine time + tool change = cost). But I do have these little "Made in USA" decals I can put on there if you really wanted me to. See pic of FL350 intake #1 with the decal. I've just been putting one of them on the bubble wrap just because. They cost literally 3-cents each, lol. I'm glad the machine shop let me take the first piece home to play around over the weekend.

Yeah stick one on mine but where you can see it from the top, that MFG should be proud they are made in the USA

Will do!

Couple comparison shots of the new intake (with big flange) versus the stock Pilot intake...

Intakes are on the cnc mill and chips are flying.


And here is the update on the flange order out of Texas, so they look to be on-time for a Thursday afternoon delivery.

Hodgkins, IN, United States 05/28/2014 12:03 P.M. Departure Scan




Many thanks,

Dan

I'm picking up the (8) intakes that are fresh off the mill today. Flanges have also arrived.

So, first thing in the morning, I will be dropping off the following orders (shipping in order of payment):

DC x2, and 0 flanges
cruz_01 x1, and x1 VM36 flange
Pilot Bird x2, and x2 VM36 flanges
afastcar x2, and x1 VM34 flange + x1 VM36 flange
Hoser x2, and x2 VM34 flange

The rest will ship out Saturday morning so as long as they're all made tomorrow.

Tracking numbers will be provided as well.

When all the parts are completed, I will get a final bill same day or a coupe days after with the final charge. If there's any savings, it will be refunded back to you.


Thanks again for participating!

-Dan

Some of the Pilot intakes have shipped out! I think the collection time at the post office is around 5pm, so if you got an email with tracking, you will see some activity this afternoon/evening. Since USPS won' give me a drop receipt, I used my phone to video-record each drop, lol. Each order is in a USPS Priority Flat Rate Padded envelope with each intake wrapped in a layer of bubble wrap, then wrapped in a 2nd layer or bubble wrap, plus a piece of cardboard. If it fits it ships, so I wanted to make the most of it.

I am picking up the remainder of the intakes this afternoon and will have the rest of the paid orders shipped out this weekend.

FYI - for those who have bought a Pilot intake kit: the flanges are installed on the intake, but the bolts are only finger-tight. Be sure to tighten them down.

And I'm glad I had the holes threaded a little deeper. Now the 16mm length bolt has more than enough depth and thread engagement.


If you would like to purchase a Pilot intake, I still have 6 unclaimed with a couple extra of each sized flange (don't worry PilotBird, I still have your other 2 on reserve). I may put a couple of "complete" intake kits on eBay just to drum up some attention (and lead interest back here). It just sucks to sell something on there and have the Buyer cough up $20 for eBay auction fees. Stupid.

Cheers!


D$

All intakes are done. Remaining orders will ship out tomorrow morning via USPS. =) =)

All orders have shipped! Check your email for tracking info.

Pilot Bird...keep me posted the other (2) intakes.

PM sent:)

Only 5 left!

The machine shop just processed the invoice, and they charged the full "not to exceed" price for the parts. I had hoped they'd knock a few $'s off their estimate since the parts were so similar to the FL350 intakes. But they also had some CAD work involved plus I made a couple changes on the fly on the Pilot parts. So the pricing is what it is. Period. No complaints from me, though -- the parts look great and I'm looking forward to the next project with them.

5 left...

Tell him you want all the chips back lmao

No sh!t! LOL

Like I said, I'm not really surprised they didn't cut me a better deal. They were slammed, their one milling center went down for 3-4 days, I made changes, plus they had to do some finish work with a small polishing wheel on a little "bump" on the flow port. Parts turned out great, too.

They turned out really good, I have not had a chance to really scrutinize them but it looks like if used with the stock reed cage its a almost perfect fit, a little massaging will be required on the right side if used with the V force 3 reed cage, when I get some time I will post up some details, THANKS so much for making these I don't see these rubber manifolds going out of production anytime soon like the OEM stuff did so this should ensure my Pilot has a leak free manifold for the next 30 years

They look so much better on the transition side than all others I have seen made to date your machine guy must know the tricks to getting that smooth finish.

Thanks! =)

I think they told me they used a "reverse lollipop cutter" for the transition.

I agree the transition side is very well produced. I received mine yesterday and they are 100% what I expected them to be, thanks again for spearheading this, these intakes are getting harder and harder to find and these intakes assure myself leak free usage for years to come!

When you heat and stretch a 39mm PWK onto the stock manifold right after the carb their is a slight choke point where it gets smaller the Dan i fold using the larger carb flange will eliminate the problem, no clue if it will be a noticeable performance increase I just know the flow will be better than using the stock manifold, removing and installing the carb should be much easier too

Yes indeed. The major ID of the VM36 flange is 39.5mm, so it fits the 39mm carb nicely. Plus the flanges are very forgiving (aka: stretchy), hence why I spec'd out this Mikuni 36mm flange for a carb 36-39mm. I wanted to make sure the carb was the pinch point and nothing else.

Got mine. It's awesome. I tried the flange on a spare PWK I have and it fits like a glove!

Thank you Dmoney for making these for us!!

Many thanks for the kind words, sir! And I'm glad it worked out so well. Fun project!!

Now I need to work on selling some new FL350 intakes 'cuz I've got a hoard of 'em! lol

Received mine they look great. Thanks for making them!!! Now all you need is a Pilot.