PorKen

I originally thought about making a thin aluminum/85 gasket sandwhich, eg. GAGAG. But phenolic would be better, I think.


Thanks for the offer! If I have to buy a sheet of phenolic, then I'll likely it have it cut locally, though. What kind of plastics do you usually work with?

BPG_Austin

Ken, we do delrin, abs, polycarb, polyprop, acrylic, renshape, Glass filled pc, nylon.. If its plastic we can probably cut it. I"d only need a spec sheet or a sample if its an exotic material. Just give me a pm if I can help.

BG

PorKen

I'm having trouble finding phenolic, so I think I'll revert to my original plan of making a composite/sandwhich spacer, eg. gasket|metal|gasket|metal|gasket, but I'll have the metal layers lasercut from 0.040 SS, which won't transfer heat as easily as aluminum.

'85 paper gaskets are <$5 per side, per layer.

Bill Ball

So, stupid question - can't the later rubber gasket be used? I would think it would be a good insulator.

PorKen

I think the S4- gasket may be intended to be insulating, but the S3 ports are oval side to side, whereas the S4- ports are oval front to back, so the gaskets won't fit on S3 heads, unfortunately.

90 S-4

Ken,
Not sure what type of phenolic your looking for but this one looks like it would fit the bill ?
Joe

http://www.mcmaster.com/

Graphite-Impregnated Garolite: Great wear properties make this material a good choice for bearings, wear pads, and slides.
It's jute fabric laminated with a phenolic resin and permanently impregnated with graphite.

18 products match your selections

Material Garolite
Garolite Material Graphite-Impregnated Garolite
Backing Plain Back
Shape Sheets, Bars, Strips, and Cubes
Opaque Black
Lowest Temperature +0° to +60° F
Highest Temperature +201° to +300° F
Operating Temperature Range 0° to +265° F
Tolerance Standard
Specifications Met Underwriters Laboratories (UL)
UL Rating UL 94HB

Thickness
1/8" | 1/4" | 3/8" | 1/2" | 3/4" | 1"

Length
6" | 12" | 24"

Width
6" | 12"


These 18 products match your selections
Length Width Sheets, Bars, Strips, and Cubes Type Each
1/8" Thickness
6" 6" Square Sheet 8520K69 $53.15

12" 12" Square Sheet 8520K42 122.67

24" 12" Rectangular Sheet 8520K12 172.09

1/4" Thickness
6" 6" Square Sheet 8520K63 $81.58

12" 12" Square Sheet 8520K44 186.41

24" 12" Rectangular Sheet 8520K14 286.24

3/8" Thickness
6" 6" Square Sheet 8520K71 $104.32

12" 12" Square Sheet 8520K46 240.08

24" 12" Rectangular Sheet 8520K16 387.05

1/2" Thickness
6" 6" Square Sheet 8520K65 $130.40

12" 12" Square Sheet 8520K48 300.92

24" 12" Rectangular Sheet 8520K18 446.73

3/4" Thickness
6" 6" Square Sheet 8520K72 $170.67

12" 12" Square Sheet 8520K51 390.14

24" 12" Rectangular Sheet 8520K52 624.96

1" Thickness
6" 6" Square Sheet 8520K67 $234.87

12" 12" Square Sheet 8520K54 545.21

24" 12" Rectangular Sheet 8520K55 861.50


18 products match your selections

Material Garolite
Garolite Material Graphite-Impregnated Garolite
Backing Plain Back
Shape Sheets, Bars, Strips, and Cubes
Opaque Black
Lowest Temperature +0° to +60° F
Highest Temperature +201° to +300° F
Operating Temperature Range 0° to +265° F
Tolerance Standard
Specifications Met Underwriters Laboratories (UL)
UL Rating UL 94HB

Thickness
1/8" | 1/4" | 3/8" | 1/2" | 3/4" | 1"

Length
6" | 12" | 24"

Width
6" | 12"


These 18 products match your selections
Length Width Sheets, Bars, Strips, and Cubes Type Each
1/8" Thickness
6" 6" Square Sheet 8520K69 $53.15

12" 12" Square Sheet 8520K42 122.67

24" 12" Rectangular Sheet 8520K12 172.09

1/4" Thickness
6" 6" Square Sheet 8520K63 $81.58

12" 12" Square Sheet 8520K44 186.41

24" 12" Rectangular Sheet 8520K14 286.24

3/8" Thickness
6" 6" Square Sheet 8520K71 $104.32

12" 12" Square Sheet 8520K46 240.08

24" 12" Rectangular Sheet 8520K16 387.05

1/2" Thickness
6" 6" Square Sheet 8520K65 $130.40

12" 12" Square Sheet 8520K48 300.92

24" 12" Rectangular Sheet 8520K18 446.73

3/4" Thickness
6" 6" Square Sheet 8520K72 $170.67

12" 12" Square Sheet 8520K51 390.14

24" 12" Rectangular Sheet 8520K52 624.96

1" Thickness
6" 6" Square Sheet 8520K67 $234.87

12" 12" Square Sheet 8520K54 545.21

24" 12" Rectangular Sheet 8520K55 861.50

PorKen

Good info, Joe. It is pricey stuff!

I can have a whole pile of laser cut stainless and '85 gaskets for the price of phenolic.

I think I'll use .020" SS, so G|G|G should be about 3.5mm thick when compressed.

PorKen

I ended up using 0.025" SS (more common). My DXFs were off by a mm between bolt holes (doh!), so I had to snip the SS at the bolt holes and space them out. I used a thin layer of silicone around the ports to glue the layers together, then put a weight on the assembly overnight.

With 3 gaskets, it's ~4.5mm (3/16") tall. I'm debating whether to go with two more, which would be ~8mm (5/16") high.



Installation wise, it looks like I'll have to remove the airbox/regulator/damper brackets or space them up. I don't think the regulator/damper brackets are necessary, and they put heat into the fuel lines, anyway. (S3s have little brackets for everthing!) I'll have to make new brackets for the airbox, or figure out another way to clamp the airbox/MAF into the MAF housing.

I may have to make a longer return hose from the regulator. The throttle body to plenum hose looks like it can handle at least 8mm spacing.

Besides the insulation, in theory, longer intake legs should make a bit more torque, and spacing the fuel injectors out might help with atomization at high rpm?

90 S-4

From everything I've ever read (15 yrs of Hot Rod ) they all say you need 3/8" minimum to
have any noticeable affect. I don't think your 3/16" piece is going to do it.. at least to the
degree your hoping for. Most of the Mustang guys use a 1/2" piece. You might want to ask
some questions on their message boards. Good luck, keep us posted..

PorKen

I only have enough SS bits for the 5/16", so I guess I might as well max it out! Next time, 6 gaskets (12 total! ) for 3/8". I think that would be the max for the stock TB/plenum hose.

I was originally only thinking about the heat, but now the additional height sounds even more promising.

BC

You feel like sharing that DFX?

PorKen

Ha!

90 S-4

I've got a DXF for the side covers on a S4 mtr, Brendan and I need a DXF
for the intake ports on the cyl heads/intake manifold of a S4 mtr -- Trade ??

PorKen

S4? I can only count to S three point five.

The S3 ports are oval left/right. S4+ ports are oval front/back, to better match the valves, so my DXF won't help you... unless you're making S3 to S4 intake adapter plates!

Are you thinking of making lower/upper plenum and leg spacers for the S4+ intake?

PorKen

OT, but as I was looking over the engine last night, it occured to me that we all need new, taller, cast/billet cam covers (or a spacer + additional gasket) for more internal volume, and external oil drains...