Homemade manifolds for dual 28s

[scottf1887]

I was hoping some might be able to help me out before I start hacking up manifolds. I've been searching for 40hp dual manifolds with either no luck, or not wanting to spend the money they're asking. Looking at my manifolds, the stock tube and flange that the carb mounts on has almost the perfect curve. Can I not just cut that tube, weld on the lower flange to the head and call it a day? I haven't been able to find too many homemade manifolds, but this seems too easy. Worst case I have to rotate the flange for the correct carb orientation and fabricate a linkage. Please tell me if I'm missing something here. Thanks for the help!

[[email protected]]

[scottf1887]

Thanks, I'll be sure to post some pics as the build progresses. Luckily I've got a stash of quite a few junk manifolds that I feel ok cutting up. I appreciate the info, and if anyone has any pics of ones they've made I'd really appreciate it. Thanks!

[Robert Chambers]

Hey I just saw this today here on the Samba: https://www.thesamba.com/vw/classifieds/detail.php?id=2234873
Good luck with your project. Hope to see pictures!
_________________
'63 OG 117 Herbie Replica
'56 Euro Oval Deluxe
'52 Standard Zwitter
'63 OG 117

[scottf1887]

Wow! Thanks for sharing! Now my mind is working on building manifolds though...I'm sure I'll regret it but I think I'm going to give it a shot with the manifolds. Thanks for the link and I'll start posting some pictures this weekend of the build.

[Brian Anthony]

Last year I made a set of 40 HP manifolds for a customer. I thought I had more pictures of them but I could only find these four. I made them complete including the base at the head. I sliced up the tubing at the base to reduce it to meet the small head port. I weld built up the base and machined it to fit nice and snug in the head. The ID of the manifold at the head is the ID of a used manifold to head seal. The heads were ported out to this ID also. This is a larger ID than the stock manifold end castings. All flanges were cut from 1/4" plate. All these pictures are of the right side manifold which has an offset to make sure there wasn't an interference with the deck lid and air cleaner. Sorry I don't have any installed pictures. The boss wanted them painted black so they just didn't show up in the pictures.

_________________
1965 Double Cab
1967 Bug, Sedan
1967 Bug, Convertible

I’m not old, but I once knew a man who was alive during the Civil War, and he once knew Revolutionary War veterans.

[Rome]

[Brian Anthony]

Rome: "-Did the customer have a stale air fan shroud on his engine so that there was slightly more room to the sides of the engine compartment to fit the 28 PICT carbs sideways?
-Did you/the customer use 36hp oil-bath air cleaners, or modern chrome ones?
-Scat dual carb linkage?"

Yes the engine had stale air heater boxes and fan shroud.

The customer was going to install 36hp air cleaners but it left the shop with chrome air cleaners.

It did have the Scat style carb linkage.

I've also made intake manifolds for 1500cc single port heads that were used with a fresh air fan shroud and modified 40hp air cleaners. You just have to mock everything up before you weld it out.

A balance tube was used in both set ups. On the 40hp it was run on the front side of the fan shroud and on the 1500cc it was run on the rear side of the fan shroud. On the 1500 I used a ball valve in the balance tube to make the carb synchronizing easier. On the 40hp the balance tube was a hose that ran between the manifolds. To synchronize this set up I just clamped off the hose.

_________________
1965 Double Cab
1967 Bug, Sedan
1967 Bug, Convertible

I’m not old, but I once knew a man who was alive during the Civil War, and he once knew Revolutionary War veterans.

[Robert Chambers]

Very nice super clean set up and work!
_________________
'63 OG 117 Herbie Replica
'56 Euro Oval Deluxe
'52 Standard Zwitter
'63 OG 117

[Rome]

Brian- amazing that you got your 1500 dual carb and air cleaner setup to fit despite fitting the engine lid rain guard! I remember your photos of that engine when you first built it.

Have you considered making a small production run of the 40hp dual carb manifolds to sell? Maybe a set of 5, just to test the water? I think there's plenty of interest due to the lack of availability of new manifolds. Original ones like TDE or Riechert are hard to find and tend to be $$.

[Brian Anthony]

Rome, I'm too busy with current projects to start anything new. My younger son and I are building up a '69 IRS pan with a Porsche 5 speed trans and a turbo Type 1 engine to go in his '67 Bug sedan. I'm also trying to rebuild my '65 Double Cab so I'm covered up at the moment. But I agree, I bet there is a small market for 40hp dual carb manifolds.
_________________
1965 Double Cab
1967 Bug, Sedan
1967 Bug, Convertible

I’m not old, but I once knew a man who was alive during the Civil War, and he once knew Revolutionary War veterans.

[scottf1887]

Brian,

Thanks for the pictures, that is some impressive work! Thanks for the inspiration, I'm hoping to get to work on my manifolds this weekend. More to come, and I'll post pictures. I just buttoned up my shortblock on my 40 and tins are back from powder coating!

[scottf1887]

I wanted to post a couple pics for everyone. I may start a build thread considering I haven't found too many forty horse builds documented. I have yet to get to the manifolds, aside from initial measurements and drawings. I'm doing a poor job of taking pics so far, but I'll get better. For the most part it's been a straightforward shortblock build at this point, and I've gotten the tins powder coated. I'm using a 100 cam, straight cut gears (been on the parts shelf for 4 years, so why not) NOS lifters, rebuilt and balanced rods from rimco along with a stock crank and flywheel that has it's first cut and been polished all dynamically balanced together. Going forward I have a nice original KS 83mm big bore kit, and I'll be picking up my rebuilt stock square boss heads on Saturday. Once all of that's in place the carbs will start coming together, as well as maybe a small diameter merged header build. I'll be sure to post more pics and document it. The best part is this is a fun build, I don't even need the motor for my cars...so going to take my time and do things right.

[anthracitedub]

I’m in the process of building one as well... I’ve got two more in the line up and that should be enough 1200s to last me the rest of my days. I too would like to see more build up threads on these fun little engines... since the current build is almost a long block and the tins are finished (almost)... I may document my next one.... already have the case, crank, rods and square boss heads... just gotta get cam/lifters and rod bearings.
One of the future builds will have dual carbs... I tried to build a set many years ago but I scrapped the build because of lack of tools and skill... they weren’t looking like the picture in my head😁... I have all the flanges and tubing, plus a few pairs of pci and pict with 6v chokes depending on which way I go.

Crusty tins

The 009 is just a mock to keep the drive in... I have the big cap dist.

Just gotta finish up these pieces.

[OMT]

Manifolds made from 45 degree copper tubing and steel manifold ends.
This on a 36hp, should work for 40hp with early shroud.
Al

[earthquake]

Here's a set I am working for a 36hp for my dune buggy...

they do need a little head modification to work through, they will have a "D" shaped port, My carbs will have bigger vents and a little blending work.

eQ
_________________
74 CLASS 11 LOOK-A-LIKE
69 DUNE BUGGY
79 INTERNATIONAL SCOUT II
05 SCION XB SERIES RELEASE 2[#437]
95 Chevy C3500 dually
98 Ford E150
Link to Kelly J. Nolte 3/20/53 - 11/6/08
https://time-zonelabs.blogspot.com/p/about-kelly.html
DEATH TO CHINGERS!
[From a military recruitment poster in the novel "The Stainless Steel Rat" By Harry Harrison]

[Huntd105]

hello everyone. today i decided i wanted to add a carb to my 1960 beetle i have spare 28pci's, i can make the manifolds, ive got some good ideas for the throttle linkage, however im stuck on the manual choke! . i see on an earlier post here that the manual choke seems to have just been removed?

[Robert Chambers]

From my experience you do not need any choke unless you reside in a very cold climate. It does take a few minutes for smooth idle warm up with out any choke. Remember the dual intake manifolds are usually short and quick to warm. If you look at pictures here on the Samba, the Dietz kit offered back in the '60s had a single choke hooked up to one carb! The AutoTechnik dual kit had braces formed to hook up to the original exhaust outlets to the OG single carb manifold. Just search the Samba and many ideas can be found. Good luck. Please post pictures when you make progress.
_________________
'63 OG 117 Herbie Replica
'56 Euro Oval Deluxe
'52 Standard Zwitter
'63 OG 117

[Huntd105]

Ok yeah thats what ive been doing sesrching theres just so much on here .. well i live in England and can get rsther cold