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Old 10-05-2010, 10:26 PM   #1 (permalink)
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Thumbs up DIY thermal intake manifold gasket

Decided to make one and share with you guys!

Some time ago I noticed in local shop thermal gasket sheets. They weren't cheap, but I thought it would be for future needs and bought smallest sheet available (which was about 1.5x1.5 meters and 2mm thick). Paid about $90 for it.. It is called "TEMAC" Temaplus (http://www.temac.cz/produkt.aspx?pid=6)

Tools / materials needed:
* sharp knife
* gasket material
* dremel (desirable)
* hammer
* pen

1. First thing to do is take intake manifold and measure approximate flange dimensions (add 1cm on each side), draw rectangle on gasket sheet and cut it out with sharp knife.

2. Put intake manifold with flange on gasket rectangle you just cut and draw shape of flange on gasket.

3. One of the the most important part is to mark stud holes correctly, because you want them to be aligned perfect to fit gasket on head afterwards. I marked them with paintbrush and white paint through flange holdes. Then I made some sort of hole cutter from this little inline skate wheel/ bearing spacer and sharpened edges with dremel. Then I put it on necessary stud places and knocked out material with hammer and self made cutter.



4. I compared some brand names thermal gaskets like Hondata, GE, Blox, OBX and noticed Hondata (which I assume is the best) uses more spare material around ports. I found it to be good idea, because you have more area covered from head to intake manifold.
SO what I did.. I took pen and added ~0,5-1cm on manifold flange drawing and more cm other places where I found to be necessary.



5. Then I took old intake manifold gasket, matched stud holes with new and marked intake port shapes and coolant hole. Then drawed ~0.5cm smaller ports free with my hand so I can cut out with confidence. Cut out those smaller port marks and coolant port with sharp knife.





6. Take your intake manifold and put new gasket on flange and make sure stud holes are aligned with gasket stud holes you cut earlier. I took some 8mm bolts and taped them a bit to put them through new gasket in flange stud holes to make sure they won't offset.

7. Take dremel and cut out exact intake port shape and coolant line if you didn't cut ecact hole!



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Last edited by roberts; 10-05-2010 at 10:30 PM.
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Old 10-05-2010, 10:29 PM   #2 (permalink)
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Everything looks good





You see more gasket material sticking out of flange





8. Put gasket back on cylinder head and see if everything is aligned good



9. Install intake manifold, tighten the nuts and you are done! Congratulate yourself with new thermal intake gasket! Now take your honda for a ride.




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Old 10-06-2010, 12:59 AM   #3 (permalink)
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Nice.
We are doing something similar with PTFE again not cheap.
3mm thick and laser cut. Rep for such a superb job and the pics.
Are you going to log the changes in IAT after adding this ?
If you are im in for the results.
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Old 10-06-2010, 05:25 AM   #4 (permalink)
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wow, very nice diy right thur
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Old 10-06-2010, 05:26 AM   #5 (permalink)
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Great writeup! How does this benefit someone over buying say a hondata or other brand of thermal I'm gasket?

Edit* post 600

Edit#2* just read it was 1.5m x 1.5m...how many gaskets do you think you would be able to make?
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Old 10-06-2010, 06:04 AM   #6 (permalink)
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Glad you like my writeup!


Well, I don't really know how much exactly I can make out of that sheet, but I guess more than 50 easy. And it's not just intake manifold gasket. I can make throttle body to manifold gasket and similar if I need it. I will sell pieces of material for sure to my friends and other Honda members here in my country if they will need some. Actually I would be glad to spend $10-15 for just small sheet of this gasket material instead of spending $90 and holding it in my apartment. It's just 1.5x1.5 meters was smallest available.

rdc: As for temperature changes. Too bad I didn't take any measurements of intake temperature before, but from what I can tell I can feel the difference with my hand when I put it on manifold! It is noticeably cooler.
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Last edited by roberts; 10-06-2010 at 06:07 AM.
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Old 10-06-2010, 06:09 AM   #7 (permalink)
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That's awesome I'm definitely gonna look into this
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Old 10-06-2010, 06:12 AM   #8 (permalink)
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now do a tb to mani gasket!

very nice diy i like!
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Old 10-06-2010, 06:23 AM   #9 (permalink)
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Quote:
Originally Posted by rdc View Post
Nice.
We are doing something similar with PTFE again not cheap.
3mm thick and laser cut. Rep for such a superb job and the pics.
Are you going to log the changes in IAT after adding this ?
If you are im in for the results.
Why PTFE. It is very expensive and very prone to cold flow which will cause it to allow the bolts to lose clamping force and come lose.

Nylon or fibreglass or even plywood soaked in polyester resin to seal the end grain would be a much better choice.

All plastic OEM manifolds are Glass Filled Nylon, mostly Nylon 6.6 because of it's good heat and cold flow resistance. They still use steel tubes moulded into the bolt holes to eliminate cold flow from allowing the bolts to come lose and create air leaks.
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Last edited by patprimmer; 10-06-2010 at 06:29 AM.
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Old 10-06-2010, 06:27 AM   #10 (permalink)
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Nicely done.
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Old 10-06-2010, 06:39 AM   #11 (permalink)
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nice job! Dang, I was hoping to see back to back IAT's but o well. You should cut and sell these. Make a combo package for IM and TB gaskets too!

-Luke
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Old 10-06-2010, 06:46 AM   #12 (permalink)
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Quote:
Originally Posted by lkailburn View Post
nice job! Dang, I was hoping to see back to back IAT's but o well. You should cut and sell these. Make a combo package for IM and TB gaskets too!

-Luke
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Old 10-06-2010, 06:51 AM   #13 (permalink)
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helluva diy sir. i'm def in for the difference with the IAT.
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Old 10-06-2010, 10:54 AM   #14 (permalink)
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Quote:
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nice job! Dang, I was hoping to see back to back IAT's but o well. You should cut and sell these. Make a combo package for IM and TB gaskets too!

-Luke
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Old 10-06-2010, 03:45 PM   #15 (permalink)
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Dang! Baller status for not much money. I like!
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Old 10-06-2010, 03:46 PM   #16 (permalink)
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nice job! Dang, I was hoping to see back to back IAT's but o well. You should cut and sell these. Make a combo package for IM and TB gaskets too!

-Luke
That would be awesome, by the way. I'm sure a lot of lazy DIY'ers would buy some.
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Old 10-06-2010, 04:10 PM   #17 (permalink)
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If you want a free set of gasket hole cutters go to your nearest gun range and ask them for some empty shells in various sizes from 9mm up to .50cal. Be sure they have been fired though. Lol
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Old 10-06-2010, 04:35 PM   #18 (permalink)
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If you want a free set of gasket hole cutters go to your nearest gun range and ask them for some empty shells in various sizes from 9mm up to .50cal. Be sure they have been fired though. Lol
Lol good idea.
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Old 10-06-2010, 05:22 PM   #19 (permalink)
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anyone got some tech data showing these things even make a damn sight of difference?

Nice DIY none the less! Hella dope Intake mani. that Venom? Or Golden Eagle? or some custom piece?
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Old 10-07-2010, 12:25 AM   #20 (permalink)
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That's my Venom IM

I am currently working on some d16z6 / p29 piston project for my friend and we will put stock IM gasket and take IAT readings and will make thermal later and I will be back with temperature readings!
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