Boss 302 Inline Carburetor System Lost Foam Casting

[@adambergendorff2702]

Only 10 min. into the video and have to stop and say your work is phenomenal, and 99% of people have no idea how much work goes into your manifolds!

[@mikehutchinson9318]

Amazing workmanship..I have not seen an autolite inline carb setup in 45 years..

[@loganshotrod4x464]

You accomplished something that I have only dreamed about. Much respect! Firepower Hemi parts, B/RB intakes, custom Big Block Chevy parts… my god, the possibilities are endless! 👍😎

[@n1352-m1i]

I must say this is very impressive. And a single man operation, for such an intricate and large part, so accurately cast... Your setup is very professional, very inspiring and motivating:you make it look too easy!

[@kellycoffield533]

I've been at it for a while so it does appear easier than it is if casting a part like this is your starting point. If you are willing to start out with smaller parts understand and develop the processes, then moving up is much more realistic. Everything becomes more difficult for a hobbyist as size increases mostly because it's just hard to handle and manage the mold mass, and molten metal management, but once you have the processes down, it becomes all about you ability to make the patterns.....which isn't a trivial matter for a part like this......but it can be done in a garage shop. Best, Kelly

[@matthewmoilanen787]

I used to work for a company that built transmissions and CVT clutches as a designer drafter. And I must say that I'm very impressed with your work and design skills. I'm also quite surprised by the amount of equipment you have for your chosen hobby (obsession). Very nice work sir and thank you for making these parts for posterity.

[@merylpelosi8485]

Another masterpiece. Another advantage to having a raised floor/non match ported runner is helping to kill reversion in the runner with large duration and overlap cams. Your castings come out so smooth, I'd be afraid to try to improve flow by polishing. This whole process is so interesting.

[@kellycoffield533]

I left the runners as-cast. They're pretty nice. I did sand the internal runner surfaces of the foam pattern. That only takes minutes for foam and I could do it when the pattern internals were exposed........much harder to work the metal in tight spaces after the fact. Best, Kelly

[@cujet]

I love it! Would love to see this on a dyno. I really like Webers, and this design seems like a good one!

[@johnrodriguez473]

Now is the chance to do away with pain in the butt thermostat housing design. Make it so it will accept a LS thermostat and remove the bypass port completely. Add a couple water temp housing sensor pads for future fuel injection. Very nice work 👍

[@kellycoffield533]

Certainly easily done, but since it's a 50 year old carb, for a 50 year old engine and collector car, the customers are more interested in compatability/ease of installation, and have no interest in modern amenities like EFI......so not likely to happen. Best, Kelly

[@n.b.p.davenport7066]

That thing looks great I would have loved to have one back when I was fiddling around with the cars

[@roughedge-machineworks]

I really like these longer videos, format allows for better understanding of your process.. :)

[@kisoia]

It never ceases to amaze me what you can make out of a chunk of foam - great work Kelly, thanks for the video :)

[@Biokemist-o3k]

Absolutely fantastic my friend!!!

[@Mrtrunks]

Thank you making such detail videos.

[@danycage6457]

Amazing work Mr Coffield... its matter of time to see a new video titled as "Engine Block Lost Foam Casting" and GREAT! you will have a entire engine DIY!

[@david929190]

Your casting and machining skills along with the equipment is a marvel.

[@skyfreakwi]

As always top notch casting. So SO glad you got the audio cleared up. I mean I still watched them all, but it hurt. Thank you your work is inspiring!

[@Rick.123]

Amazing, your casts looks like magic. I wish could make something similar in the future. Thank you Mr Kelly

[@tadeustentakel4189]

Hello kelly.what an amazing work.perfekt work👍👍👍greetings from germany

[@kellycoffield533]

Danke für die netten Worte, mein Freund.

[@wikusdp]

Awesome as always! Greetings from New Zealand.

[@jimurrata6785]

Do you watch 'Odds And Ends Machining' ? He's a Kiwi doing motorcycle engines and the like using a very similar process, but seems to hire the casting out.

[@371francis]

Wow. This is really cool. Congrats on a great video and project!

[@sicsempertyrannis1849]

Amazing workmanship. This is something I'd love to be able to do myself, but unlikely to happen.

[@nils1953]

I would love to see some more of your post processing work. You just showed pictures, but I think the machining and heat treatment is interesting and I'm sure there's lots of knowledge you would be able to share if you wanted to.

[@kellycoffield533]

For heat treating the furnace I built is much more interesting than the HT process. HT is literally just putting it in the furnace set for 460F for 9hrs......but, it is certified A356 ingot so I do know the appropriate HT schedule. T5 poses no risk of damage to the casting, does not require controlled cooling, and achieves a large percentage of the improvement in strength and machining compared to T6. Occassionally I will add grain modifiers and refiners like TiB and Sr. For machining, the fixture is really the key. Other than that it's just 3-axis manual milling. I'll see if I can work a little more on that into future projects. Best, Kelly

[@nils1953]

@@kellycoffield533wow, thank you for the detailed information Kelly! Is there a forum post about your HT furnace aswell?

[@kellycoffield533]

@@nils1953 Yes, there are links to my furnaces in the signature section (at bottom) of any of my forum posts. Best, Kelly

[@ExMachinaEngineering]

Another beautiful piece there Kelly. And another amazing work on CAD and CAM. Thanks!

[@kellycoffield533]

Thanks my friend. I am still indebted to you and grateful for your CAD help. Take care, Kelly

[@matthewq4b]

Very nice casting. We need to have another look at the in line autolites it would be nice if they could be reworked in a modern interpretation and casting for more streetable operation and CFM's

[@kellycoffield533]

Streetable can be in the eyes of the beholder. From my perspective they are plenty streetable but the larger version of the Inline Carb was built for IR induction and never intended for open plenum intakes, and they are "streetable" too at least for those that view IR as streetable. -Many systems running around on the street. Best, Kelly

[@blackcoffeegarage]

This is fantastic! Oh how I'd love to do something nuts like this someday... maybe a hyper-pak/long ram twiple Weber for a Slant Six... just insane!

[@driverjamescopeland]

Always love the idea behind the Autolite inline 4. I had high hopes when Barry Grant debuted Badman carb and intakes... but sadly, they went belly up before it became a production reality (I think the might have shipped all of maybe 4 units).

[@lawrenceveinotte]

Great video, I'm getting closer to casting, for starting I'm just going to use old cast engine parts, get my system figured out.

[@kellycoffield533]

That's a good plan. Best, Kelly

[@bengelman2600]

Work of art man.

[@shortchange26]

That Autolite inline four is worth a ton of money.

[@shadetreemechanicracing22]

I just picked up a small smelter. I'm starting with small parts like thermostat housings, so I get some experience casting. Before I move up to intakes.

[@eliteman7685]

A lot of amazing work!! Attention to detail is outstanding. Great video explaining the process as well. Casual observation: I’d much rather see you using a Coffing chain hoist over that little wire rope hoist!! A JLC series would work well but you would have to slightly raise the gantry crane height. That wire rope hoist and tiny cable just makes me shudder at the idea of handling molten metal flasks.

[@kellycoffield533]

It's only 150lbs of shank, crucible, and metal on an 880lb rated hoist. The cable would have an ultimate strength of multiples of that....pretty conservative, even for cheap Chinese stuff.

[@eliteman7685]

Fair point. I spent a decade in the overhead crane business and galvanizing plant cranes and the abuse wire ropes take in casting facilities but I was dealing with giant overbuilt foundry cranes. Me being me I saw that lil dude and my brain went panic mode 🤣 Been watching your 351c intake videos. Great stuff and have a good one!

[@j1mbobtech]

I was very impressed with your work...

[@russtuff]

Amazing work as always, thank you for sharing!

[@danielschumann2548]

Amazing. Love watching these videos.

[@TallGarage]

magic man, pure magic

[@dp4racing]

Awesome work! Perfection! My hat’s off to you!

[@overbuiltautomotive1299]

very inspiring and motivating God bless

[@joncloud2034]

Love your work. What makes it even all the more enjoyable to watch is the fact that I'm a Ford guy. Awesome stuff. Would love to talk with you about a project. A460 head tunnel ram. If you see this please contact me. I'd love to discuss the project with you if possible. Jon

[@kellycoffield533]

Seems like there is already plenty of options to choose from out there. Does the world really need another 460 TR? Best, Kelly

[@billjenkins3699]

WOW I am impressed

[@DragBoss351Cleveland]

Hey Kelly, awesome video, so cool, would love to make a single plane intake. Does that process work for a single plane?

[@kellycoffield533]

Yup. My next project is a 351c version of this intake. Right up you alley DB. Best, Kelly

[@billvose7360]

Very impressive! I have actually worked on an 850 CFM Autolite in-line carburetor. Owner was running it on our local (Hampton VA) 3/8 mile track using the Ford "Cross Boss" intake with the single carburetor top. A question for you, have you done any EFI manifolds? I have an idea for a 460 one based on the early 90s Chevy 454 EFI intake. I worked for Newport News Shipbuilding in their laboratory and spent more than a few hours in their foundry.

[@kellycoffield533]

Yes to EFI, mostly IR EFI. Best, Kelly

[@gregtaylor6146]

Fabulous Sir, thank you ..... Subbed!

[@jamest.5001]

I'd love to have a intake this style one to accept a pair of 350 or 500cfm Holley carburators, or throttle Bodies! Or custom design and build a inline Holley DOMINATOR! Use all the Holley parts , and open up the throttle blades to two ovals and possibly add a 3rd down leg booster making a roughly 1300 CFM carb or 1800 CFM throttle body, run multiple accelerator pumps, with the option of using 4, 30 or 50cc pumps. Or the ability to use both with a progressive linkage for the pumps. Use a 30 for just off idle, going easy or faster off idle start the use of a 50, then about 1/3 throttle, the 50 come into play. With a final 50cc pump for the final 1/4-1/3 throttle, with the fuel being sprayed not squirting using a two stage annular booster besides custom throttle blades and boosters basically everything besides linkages and shafts be Holley parts. Possibly cast fuel bowls for additional pumps . The throttle body for efi would be best mount the 1500 injectors on the bottom of the ports about 1.5-2.25" up the runner. From the flange face. With the air flowing over a small lip over the injector hiding the air from the injector with a 1/16" thick flap basically with a 1" cavity adding to the injector body spreading wider than taller to create a Venturi over the injector where a 3mm hard line can be plumbed to each injector to either measure vacuum, or go to a single 1/2" tube to form the vacuum port for the brake booster. Theory is the Venturi adds vacuum especially for engines with large cams. It's not going to work at idle but should just off idle, 1200rpm or so. But at full throttle high rpm it should provide plenty. It's a crazy idea, but the fuel distribution should be exceptional. Allowing a booster per intake runner roughly. A carb or throttle for a inline engine even better.. especially with a custom intake designed with a 1" exhaust pipe running through the plenum floor inside a finned chamber floor helping with flow . For race apps the heated floor can flow ice water through it. And flow testing of the plenum and ports using wet flow. Using 5 gallon columns of water flowed through the throttle from 6-8" dia. Pipes 10' tall. Possibly under air pressure. Using exact amounts of water over each throttle, and about 3-15 psi. Measure the amount of water pressure of the water, swirl and /or tumble of the water from each intake runner. Also I know it's not so simple, but cast an aluminum head for the Chevy 250 from the late 70's early 80's with the integrated intake manifold. Don't know what (or if) they were thinking. But keep the rocker geometry of the stock head. Cast a custom valve cover that is it's own pattern and shape . Maybe a similar cover as the early to mid big block Chevy. Only longer with about 4 additional bolts. And seal with a spot of rtv. And a prong cord in a groove. Make the ports and runners similar to a modern LS or LT engine. With taller ports and a Cross Flow design. Using a 1" exhaust pipe running from cylinder. #1 and dump in , #6 with a valve to shut off flow when hot. Possibly use the LS valves 6.2L with a similar chamber shape as the LS. Possibly adding angle to the valves basically like putting a LS head on a i6. The power gain should be exceptional. Keep the exhaust on the right side, with the intake on the left and even go as far a custom ground cam with the intake and exhaust in the proper order, and possibly change the firing order. If it works out better. Maybe convert to a roller cam. Build a cam using disc of tool steel to form the journals , and offset bore 12 to form the lobes. Possibly use a bronze gear pressed on the splined shaft. With about 6 splines, about 1.5-2 mm deep chill the shaft and heat the disc and lobes to about 300°F or so to get them to slide on under mild pressure, possibly require a light tap with copper/lead hammer. Using the original camshaft to align the lobes and journals. Possibly Tig weld or laser weld the lobes and journals in place after cooling and testing interference fit tightness. A spot weld in the valley of each spline should be plenty to prevent any movement. Possibly use a hollow shaft with the ends plugged. And have oil holes and grooves possibly using EDM on the base circle and journals. Especially if the use of flat tappets is required. And possibly bore out the lifter bores to install brass bushings to accept stock hydraulic roller lifters from a V6/8, or other modern engines. Possibly use big block Chevy roller rockers with 1.7:1 or 1.8:1 ratio , also using a stud girdle. That also works as a heat sink, also hold a bit of oil to drop into the to rockers and on the valve stem rocker contact area. Maybe use a shaft mount rocker set-up. With hollow shaft flowing oil to everything but ball studs is better, because the chambers can be rotated about 45° to produce a semi-hemi twisted wedge head. This will possibly cost more to have custom pistons made. Mays well have custom light weight scat rods about .200" to . 300"+/- longer rods with light weight pistons short skirt with tiny ring packs, something like 1mm , 1mm, 2.5mm, with floating pins and bushings in the rods. A main girdle from stress proof steel, with main studs. It's turned from a carb and intake, to casting half a engine! Haha, sorry for all the rambling. But I'd totally love designing and building a engine! Even if it was a proof of concept type thing, without the water jackets, but this is what welders are for.. mill them out and enclose the water jackets.. the shallow and somewhat wide valve cover would look awesome, with 3 350 Holley carbs on a log plenum intake roughly 3"x5" at a bit of angle so the corner is in the middle of the port the runner about 6" to 8" long made from modified 2.5" tubing, bent in an arch split and shrink a bit, to make a long funnel. Rack carb gets a signal from every cylinder, yet each cylinder has its own Venturi and booster. Or throttle valve. Mount a couple 60 mm turbo's on this thing with a intake plenum over the carbs. Modified to be blow through. Or efi. 150-200 hp per liter should be very easy. And still be totally well mannered on the street , connect it to a 5-6 speed in a ck from the 70's -80's it's going to be awesome. And no one is going to know what kind of engine it is. Maybe mill a bowtie in the valve cover, with 4100 in it. Sorry again, thanks for the great video..

[@stevehansen5477]

Where do you get the carburetors? They are a rare peace.

[@68f100ranger]

Id love to have just the base. It would be a easy way to fab your own intake.

[@blownaway4371]

Are you setup ONLY to work Ford items? I was trying to adapt 4 Dodge Intrepid 3.5 throttle bodies to the top of a 90's GM LT1 style v8. Then a divorce happened, (after 31yrs) and a lot of dreams with it. I'd LOVE to be an intern with you in your shop!! Gonna binge watch your videos while at work 😅

[@kellycoffield533]

It wouldn't necessarily have to be Ford engines but there is a close tie between Ford and Inline Autolites Carbs which I do a lot with, plus, I have all the dimensional data for Ford platforms. The reverse engineering to get reliable dimensions is a large part of the task. Best, Kelly

[@blownaway4371]

@kellycoffield533 What a WONDERFUL talent and knowledge that GOD gave you! I looked at the LT1 intake since most of the manifold is already there. And it would just be 4 throttle bodies. I'd love to make a ITB setup for the Big Block mopar !

[@godsowndrunk1118]

That looks like it could have come from Ford High Performance back in the day.... In other words, Cool.

[@kellycoffield533]

That's exactly my aim.....a period part that could have been available in the over-the-counter-program, and should have been, but never was. Best, Kelly

[@jeremycrisp4488]

Beautiful!

[@herbhartman7528]

Where you at in Iowa? I’m in Woodward, would like to visit!

[@vinmandich7756]

Only question for you is do you klnot worry about puddling fuel in the plenum at the runner opening where in camera it looks like there is a lip or ledge at bottom of runner mouth also adding a velocity stack at port mouth or extending the runner into the plenum I would love to test these intakes on my superflow. Great work one he'll of a skill to have casting intakes has always gotten my curiosity. I have built a handful of sheet metal aluminum for various engines alot of time goes int it it's not easy alot of math figuring taper length for runner to port volume as well as angle

[@kellycoffield533]

The discussion does come up from time to time, but in short, no, I find in practice, short of pouring raw fuel into the carb, it just doesnt happen. 90%+ of the installations are passenger cars and the rear of the plenum floor is typically 1/2 - 1 1/4" lower than the front, so if such a thing were to happen, it would affect the rear two cylinders, and as far as plug reading and exhaust temperature reading goes, it doesn't happen. In large plenum/ram box type intakes keeping fuel in suspension can be more of a problem, but that's usually because velocities are very low and there are areas of the plenum that are completely inactive. By comparison, other than perhaps very long idle periods in very cold whether, this plenum is so much more active, the ability for liquid to exist is remote. I could have removed the steps with light sanding but decided to leave them, because if such thing ever did occur, it likely would send any droplet back into suspension at the cost of a little seperation........but that would be in the lower less active portion of the runner. -My 2 cents. Best, Kelly

[@jameswieler3295]

Amazing!

[@zumbazumba1]

Amazing work! What would people use in the past to make such complex shape when they didn't had cnc machines? Styrofoam was invented in 1944 ,how would people cast such complex part for ford model T for example?

[@kellycoffield533]

I made this intake before I had my CNC Router. The pattern for this was made with only a hot wire and hand guided patterns on woodworking pin router. kzbin.info/www/bejne/a4vSfoJnqaiqrMk Both of these tools would have been available in the 1940s. Here is a video of a carburetor pattern I made on my pin router with lot's of footage....all manual machine operations. kzbin.info/www/bejne/r6u8m6Wiqsx8aLM Best, Kelly

[@jimurrata6785]

The model T? Lost wax has been around since at least the Roman empire (I don't know how long before)

[@kevinmarzetta7501]

Your abilities are amazing and I have examples to back that up 🤩 feels as though I’ve finally meet that person ( Kevinsownboss 😉)

[@cascodrew]

Can you make one for a small block Mopar!? Please!

[@WesternReloader]

Pro level here

[@TheGrosen84]

Could you do different cab adapter plates, for example 4 single barrel holleys or rochesters?

[@kellycoffield533]

If they could be lined up on

[@Rch5.0]

Can you get the inline autolite carburetors

[@harrellv10]

Have you ever cast aluminum cylinder heads? Would you be willing to try it? I’m dying to figure out a way to get some aluminum heads for my International Harvester 345!

[@kellycoffield533]

No, No not that one, and aluminum heads for a IH345? My goodness why?

[@villeamiettinen]

Is are those used to made sandmold?

[@dylanbeaty8338]

What brand smelting furnace do you use?

[@kellycoffield533]

It's self made.

[@dohcsmr1175]

What would you charge for a manifold? I believe you can sell them. I would buy one. Well done and all the best.

[@kellycoffield533]

Go to www.inlinecarb.com and contact me at the email with that domain. Mention this post. Best, Kelly

[@beachboardfan9544]

How do you account for shrinkage as the casting cools? Do you machine those foam cores X amount oversized?

[@kellycoffield533]

The pattern is made 1.3% larger than the intended casting size. Best, Kelly

[@MultiRyan117]

What refractory coating do you use to dip your patterns in?

[@kellycoffield533]

Search my channel. There is a whole video dedicated to the subject of refractory caotings. Best, Kelly

[@RayMellin]

Do you make a dual quad for 9.5 deck with Cleveland heads ?

[@kellycoffield533]

I've made a CAD model similar to an FE tunnelwedge in appearance. I'm just not satisfied with it.................yet, and have other projects ahead of it. Best, Kelly

[@TheGrosen84]

I'd buy one...

[@SRFirefox]

Been following you for a while now and I'm curious if you think you'd be able to cast an engine block or head using this technique? Specifically you, I certainly wouldn't be able to!

[@kellycoffield533]

Yes, but I'd need larger melt and molding, capacity. I have no plans for such at this time. Water jacketed engine blocks and cylinder heads are routinely being commericially cast in industry now by the lost foam method....just not as much in the US. When the castings get large, the price of admission goes up rapidly, especially for hobbyists. Best, Kelly

[@SRFirefox]

Thanks for the response. Cool to know the method scales up reasonably well. Cheers!

[@georgedreisch2662]

I’m interested in how to contact you, regarding a casting project?

[@MRGF78]

I don't know if you've said it before, but how big is your crucible??? Thanks

[@kellycoffield533]

It's a Morgan Salamander Super A60 = 60lbs of Aluinum. When I pour intakes, I typically melt 30lbs. It's much easier to control a pour if the crucible isn't brim full. Best, Kelly

[@ericjohnson8625]

Oustanding

[@seancollins9745]

I am wondering if you'd be willing to do a small batch of intakes for me???? It's for a BMW engine, i have good 3d models

[@kellycoffield533]

Sorry Sean, thanks for the interest but I have too many projects going already. Best, Kelly

[@seancollins9745]

@@kellycoffield533 that sucks, we haven't been able to find a small foundry, if there's anyone you can recommend send the contact my way. thanks

[@kellycoffield533]

@@seancollins9745 Drop me an email and I'll give you a contact. My email is on the front page of my website www.inlinecarb.com Use the address with the weebsite domain. Best, Kelly

[@johngibson3837]

Never seen you till today, beautiful work mate and excellent vidio , question how did the manufacturer's make there moulds I'm guessing the outside is many pieces as always see were they've ground of flashings but how do they do the runner's, would love to know how as they were making thousands

[@kellycoffield533]

@@johngibson3837 They were traditional sand casting with a hard pattern for exterior features and "core prints". Seperate cores were made to form the interior features and placed in the core prints prior to the mold halves being assembled and closed. Best, Kelly

[@MaxWash-f6o]

I would like to talk to you about working together on a project if your willing.

[@kellycoffield533]

Already have more projects than time. If it's Inlne Autolite Carb on a Ford engine platform possible, otherwise unlikely. Best, Kelly

[@anandarochisha]

I'll take 4 please..😊