Are you using heat to help preform the lexan?

Lorena, Texas (South of Waco)

Yes, this stuff is strong, when I heat it hot enough to make it pliable and try to shape it it cools fast and gets hard (about 5 seconds). I'm going to try to form it cold (?) I can bend it in a metal brake (cold) and it bends just like metal. 

If you use a Benzene torch and keep it moving across the lexan, it will not cloud up.  Run the benzene across any cuts, and the edges will smooth out and come clear.  Just don't over do the heat in one spot.  It works on other acrylics, also.   Joe-JDC

JDC

Working today, here are some failed attempts at forming the intake runners.

More tries (closer), however after more study I'm going to make a steel forming plug that I can heat up and switch material

Merry Christmas everybody!

You are doing some very interesting work on this Setup. I've been following along and can't wait to see what's next. Good job Clif!

       A  L  A  N   F  R  A  K  E  S   ~  Tulsa, OK    

Thanks, this manifold is killing me, and I got sick for a week.

Have you considered using clear plastic tubing in 1 3/4" diameter and cutting it to the length you need, and then installing it in a slim container and pouring clear epoxy around the tubing?  You could then remove the soft tubing, and mill/sand/file the epoxy to fit your manifold.  When I was preparing the tunnel ram for the 2016 EMC Y, I used clear plastic tubing from Lowes, cut it to lengths I wanted, and inserted that into the runners of the tunnel ram box.  Next I filled the body of the tunnel ram with epoxy, and let that harden.  When everything was cured, I used my heat gun to soften the plastic tubing, and removed them.  Blended the epoxy, and sealed it with a ceramic based paint that was fuel/oil/resistant.   Joe-JDC

JDC

That's a Idea, however I think I got it.

Thanks