Savage Chopper Build: 90 degree intake manifold

I’ve been pretty bad about posting updates to the Suzuki Savage Chopper Project, but I have been working on it and slowly moving forward. I’ve still got a long laundry list of stuff to do, but I can see the light at the end of the tunnel. The goal is to have it done in time A more complete update coming soon, once I get a nice weekend day where I can actually roll her out of the shed, but for now, here’s a quick run through of the 90 degree intake manifold I made up.

I ordered up a 1- 3/4″ OD j-bend mandrel tube from of all places. $20, plus free shipping since I ordered some other stuff that brought my order over $25. This stuff is also available at most auto supply stores (autozone, pepboys, etc..) although it was special order at all the local ones, and a few bucks more, which is why I went with amazon. If you have a place near you that has a mandrel bender, you can get them to bend you up some pipe, but it needs to be a mandrel bend. Press bends will be more oval shaped at the top of the bend, which won’t work. Mandrel bends will retain the same shape throughout the bend. Anyway, moving on…

1. Intake-100 2. Intake-101 3.Intake-103

Pics above:
1. Grabbed the pipe, threw it in the vise and took the sawzaw to it. One cut in the middle of the bend (yellow line) and then choppede up the straight part until I got the length I was looking for.

2. After the first cut

3. Finished piece inside the rubber mounting boot that attaches to the cylinder.

Now all I need to do is grab some radiator hose and clamps to attach the carb to the intake, and make a simple brace to support the carb so it’s not hanging free. Pretty easy and straightforward. I may change the bend to a 45 degree (instead of the 90) as the build progresses, but for now, this will work.

More thorough updates coming soon.

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