After receiving and fitting up the fenton headers that I purchased for my 228 with the intake manifold I'm feeling very uneasy with fitting them up correctly with their respective ports. I really don't like the original design using the clamps for both manifolds. And now with the fenton's, nothing seems to line up correctly, nor is there any way to reference their positions to match the gasket and the ports. I threw around the idea of fabricating up new clamps to help with the clamping force, but I'm still left with the accuracy of the alignment on the head.

Heres my new plan, and I'd really like some constructive feedback on this. I'd like to design a single flange and weld both manifolds to it. This would create a much more easy and accurate installation. I've checked out the clearance of adding say a 3/8" flange and there isn't anything hindering that. The real issues I see with doing this are welding the manifolds to mild steel, and the heat sinking that will occur from the exhaust to the intake.

I'm in a good position to give this a try. I'm a welding and fabrication student at our local community college. I have a decent amount of hours in all the processes and a few certifications under belt. My instructors are CWI's with decades of experience welding and fabricating in all areas of the industry and I have access to all the equipment, including a Lincoln tourchmate 4800 that I've recently learned how to operate correctly. I'm confident I can create a quality flange that will measure up accurately and meet the demands. I'm also sure that I'll have the correct guidance and tools to do the job. So I guess there isn't much holding me back from trying it. My fear is I have to scrap the manifolds or waste my valuable time pursuing this. My goal is to create a quality product that will perform and last the life of the truck as well as accomplish something different that will put my skills to the test.

I'll keep this thread up to date on my findings and progress if I decide this is worth working on.

Take care everyone,
Matt