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matt
Dodge Dakota
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9/13/2004
00:30:20

Subject: 5.9 intake manifold mods?
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Anyone know any tricks in modifying the stock 5.9 intake? I'm getting ready to port and polish one, and wondered if there's anyhting I might be able to do to boost it/s power...



.boB
Dodge Dakota
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9/13/2004
09:26:09

RE: 5.9 intake manifold mods?
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The Beer Keg manifold is designed for low end torque, and it does a pretty fair job of that. You can increase upper rpm hp by cutting back the top of the plenum walls, but you're trading low end grunt for that. Take a look at hughes performance web site.

Don't get too wild with the grinder. Just remove any casting flash, put a gentle edge on any dividers, and port match to the heads and throttle body.



prple-gaseatr
Dodge Dakota
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9/13/2004
15:29:54

RE: 5.9 intake manifold mods?
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got a modded one for sale if you want,...email me if u are interested...avengerguy@comcast.net



matt
Dodge Dakota
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9/13/2004
15:33:10

RE: 5.9 intake manifold mods?
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thanks for the offer on the modded one, but I already have two intakes, one on my truck, and another I'm moding.... and I've looked at hughes site, they don't cover the actual modifications... unless I missed it.




Sneezer
Dodge Dakota
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9/13/2004
16:12:35

RE: 5.9 intake manifold mods?
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This is from the fast4x4.net webpage that has since been taken down. I thought I had the pix, but I guess not. Hope this helps.


An alternative to installing an MPI manfiold, is to modify your stock "beer barrel" intake. This would be preferential to a MPI manifold for two reasons. (1) it is a LOT cheaper to do, and (2) the MPI is really not needed unless you're going to run ported heads and a larger camshaft.
There are a few small differences in manifolds, so if you're getting a core from a boneyard, make sure to get one that matches your generation truck. This means OBD-I (example) or OBD-II (example) controlled motor. The difference here is the EGR port on the rear left side of the manifold. So pay attention, in case you want or don't want and EGR valve. The other difference I have found is the divider length. I'm not sure if this difference is between model years or motor size, but if you're getting a core to work on, find one that has a short plenum divider (I know 99 R/T's have the short divider). If you compare the two photographs above, you can see the EGR tube in the 1st, and the lack of a plenum divider in the 2nd.
For the EGR equipped manifolds, you will want to take it to a machine shop. Have them use an end mill and cut down the divider about 2" or so, just enough to remove the EGR tube that runs from the back of the manifold to the center. I pay around $35 to have this cut out. For the non-EGR manifolds you probably won't need to have the divider cut down.
Now for the runners.... here you must consider your application. Cutting a lot of material out of the runners will raise the powerband, and reduce the amount of low-end torque. I feel if you need shorter runners, then you would probably benefit more by installing an MPI manifold. If you still want to cut the runners down, I would not cut more than 2" out of each. If you look closely at the design of how the runners lay, then it will be apparent on how much you can cut out of each runner. You will still see some gains if you do not cut these at all, so that is your choice.
Now it's time to break out the die grinder. I've used a simple Dremel tool in the past, but a pneumatic grinder and some good rotary files and drum rolls will makes things easy. Using the grinder, you'll want to smooth out the edges of each runner, and try to clean up any rough contours and casting flash. After you're satisfied, clean up everything you've ground on with the abrasive rolls. This is a process where taking your time will pay off. After you've cleaned up the runners, you'll want to radius the injector bosses. Very carefully round over and smooth the bosses where the meet the runners.
Once you're finished and happy with your results, clean everything throughly. Pay close attention to the bellypan area, make sure there is NO leftover gasket material. Then you'll want to use a sharp center punch and dimple the manifold around the gasket surface. Clean and prep the steel bellypan and set aside. Run a bead of RTV, and I highly recommend "The Right Stuff" made by Permatex (comes in a can like Easy Cheese), this stuff works so much better than RTV and is a LOT easier to apply. Then carefully lower the bellypan down, making certain to not move it around. Install and torque the bolts to spec.
Here is a pic of one of my modded ones in progress.
I've got a couple manifolds sitting in the garage for anyone who is interested in the gains, but weary of tackling the work themselves. Feel free to email me with questions and/or comments.




matt
Dodge Dakota
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9/13/2004
17:38:54

RE: 5.9 intake manifold mods?
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Cool! Thanks for the info, thats what I was after!



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