Welcome to the 99-01 Cobra Intake Fix Page

Update Feb. 2010

99-01 Cobra Intake Fix. (03-04 Marauder/Mach I)
This is the intake manifold from a Cobra that was modified by a so called expert. The intake was modified for short runners and then welded back together with too thin of plates. The plate is only .065". It acted like a drum and cracked the shoddy welds, even worse under boost.
I had the fun task of fixing this intake manifold so it could take 25psi of boost. Follow along as I fix an experts fopar.

I wanted to remove the welds all the way. The cleanest way to do this is mill the plate and the welds off. So I set the intake on a jig plate and clamped it down lightly as not to damage or mar the manifold..

I took light cuts with the end mill. This was after about 3 passes.

After about 6 passes or so I was able to get the the welds. I then milled a little more to totally remove the welds.

Ready to make a template using thicker aluminum plate. Notice the modification and epoxy that the other company epoxied the velocity stacks on. The thin side plates used the same side plate thin material.

Here is the thicker 6061 aluminum that is .160" thick plate that was used. This is almost 3/16" thick. It took quite a long time to make this plate.

Difficult to see, but I made thicker "bridges" for the side plates and also rosette (plug) welded them from the inside.

All welded up. I used 4043 aluminum filler rod. Notice the 2 oval shaped heat marks on the side of the intake. This is the rosette (plug) welds on the inside "bridges" I did.

Shot of the beads and the fixed manifold.

Fixed short runner intake with the thicker plate ready for intall on the car as well as ready for some boost. Stock intake on the bottom.