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Shaving plastic car intake

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  • Shaving plastic car intake

    Need some ideas on shaving this intake. Working on a engine swap right now, can't figure in $450++ for an LS6 intake at the moment.

    LS6 intake

    I have truck intake here

    Started chopping things off

    Gonna chop off all 6 of these ends off and smooth it over.

    This is the smooth look I'm shooting for.

  • #2
    Most people have been just using fiberglass to cover up the holes from the stuff they chopped off. But fiberglass and plastic? No thanks.

    Someone informed me that the material is made of glass reinforced nylon 66. He said that this material is capable of handling 400 plus degrees & is pretty much the same material as an 88 cent spatula from wal-mart, but with glass reinforcement.

    I was thinking maybe getting the rest of whatever I want to shave off of the intake and cop it down. Rough it up really good 24-36 grit.

    Then try reusing some of the scrap pieces I have to plastic weld into place so I can plug up any small holes. For the ends on the side of the intake(all 6 of them) I will have a sloped over hole on the side once I chop those down further to the intake, there will be some pretty big hole to fill. So thinking about buying some spatulas to try out for donor material like what was mentioned to me, plastic weld those in. Rough it up some more, then go over the entire intake with one of the many available plastic fillers.


    • #3
      Put up some pictures of what you have and maybe edit one with red lines to show proposed cuts.

      Sent via Droid Charge


      • #4
        After some more digging around I have a few options.

        1. The intake is made from nylon 66 which is capable of withstanding 400 degrees as I was told

        2. Not sure the actual temp of the intake during operation, but at full operating temperature and driving all day the intake is still cool enough to touch with bare hands (I have been searching specs on common plastic 2 part epoxy to find their max temp they can handle)

        3. I was going to try one of harborfreights plastic welders. They take back items no questions asked so if it does not work I will just return it.

        Electric one-
        Air compressor one-

        For donor material I was going to try spatulas to "weld" up these holes here.

        This is how the intake currently looks.

        Close up shot on the holes I need to close up.

        If that works out, get die grinder and 24grit roloc disc or so and go over the whole top part of the intake to bring everything down to level. Rough it up enough to give something for the epoxy to bite on to.

        Thinking about using this to smooth it over after. Hard set filler from Urethane Supply


        if the plastic welding does not work try these metal mesh reinforcing sheets to cover up the holes, then spread the epoxy over that.


        • #5
          I've tried to use air welders -- including one of the Harbor Freight units -- and found them miserable. I ended up with Urethane Supply's KC Welder Pro, and it's done several jobs perfectly.

          I don't know if that unit would work for Nylon 66, but Urethane Supply can advise you. Call their tech support (800-633-3047) and get help and advice on what to buy for your application and material. I was impressed that they didn't try to upsell me or push anything I didn't need.
          If just enough is really good, then too much ought to be perfect.

          2006 Scion xB with in-dash Atom & Lilliput 889GL -- Worklog at


          • #6
            can use an epoxy like substance called mythacralade found at body shops. its a 2 part adhesive that requires a special gun to dispense it but we use it repairing jet ski hulls. sticks to anything. also there is another product caller fiberall or something like that. again 2 part and uses a special gun to dispence and mix but has glass fibers in it already. would be good for your application.


            • #7
              Thanks for that info slociviccoupe. I will do some searching and check those out.

              @rdholtz I pretty much having something like that, but its actually called an woodburning pen.

              Found a pic on google. This is exactly what mine looks like/came with. That one from urethane supply just has a different tip on it. I also use this pen for soldering once in a while if I have to. It gets plenty hot.
              Attached Files


              • #8
                The unit from Urethane Supply has enough power to stay hot continuously, and it has a nice, broad tip. But I've read that some people have used a modified soldering gun successfully.

                It's still a good idea to call the tech support guys at Urethane Supply. They're knowledgeable, helpful, and not pushy. You can get some pretty good information on their website, too.
                If just enough is really good, then too much ought to be perfect.

                2006 Scion xB with in-dash Atom & Lilliput 889GL -- Worklog at


                • #9
                  If you use epoxy, thin it out with microspheres (Amazon has them listed as "Microspheres 0.5 gallons"). They are tiny glass beads that act as a filler.

                  You can mix them right in the expoy, and they help stabalize simliarly to glass fibers, but they are easy to sand down.

                  You can make up a mixture that is similiar to spackle, and press it in.

                  Looks like a cool project- post some more pictures of your progress if you can...
                  Zotac H55-ITX w/ 802.11n WiFi, i3-550/3.20GHz, 8GB DDR3 1333MHz, 120G Intel SSD, P2140,
                  7" pseudo-transflective resistive TS, Win7-64, Centrafuse 4.3, Elmscan Compact 6, BU-353, Rear camera, Trailer camera


                  • #10
                    Thanks for the tip Zephrant. I was actually thinking about using some. My local tapplastic store carries it and its right around the corner from my house. I usually use there chopped fiberglass and mix it into cheap body filler when I need some reinforced filler and run out of my good stuff.

                    I actually kinda scrapped this project however. I came across the lower profile LS6 car intake.

                    When I get the time I will be finishing the intake and probably sell it cause I have no use for it now. I actually have two of these truck intakes so I will probably just shave both of them for fun when I get the time. I will post results when I do. Thanks to all that helped with suggestions.

                    The truck intake on the right side above is how it currently looks after shaving and grinding some more.

                    I'm going to chop off and fill in the port in the back of the intake that's for the MAP sensor and relocate it somewhere on the back side to hide it. Going to chop off the PCV port in the middle too that's on top of the intake.