Inlet manifold flaps removal question

[Eashan]

I have removed the flaps from the inlet manifold. I need a bit of help. Can you remove the flaps inside the engine too or do these need to stay in? I'm having a remap so any codes that come up wouldn't be a problem.

[ROY]

I'm doin mine on Monday and will be removing the tumble flaps
How've you gone on removing the manifold flaps ?
Did you remove the core plugs and where did you get them from ?
Pics pics pics pics please

[Eashan]

I have had it done at a local garage and it's still there for a decoke. I will take some pics when I get it back. They have taken out the core plugs and welded the holes somehow. I will get more info tomorrow. Some of the core plugs were very loose so I rather not have them at all as I don't need them now. What do the tumble flaps do? Will it make a difference removing them? Are you doing a decoke?

[ROY]

Yep doing a decoke on Monday - got everything ready including core plugs.
How did they manage to weld the manifold its aluminium ?
I don't fancy the new plugs coming out either but not sure if i would weld the holes

[Eashan]

Yes they have welded the holes. Why is aluminium a problem to weld? I wil post pics later. It's all done now jus needs a map tweak. Who is going to map yours? I will post pics later.

[adsgreen]

Aluminium is possible to mug weld - plenty of track/race fuel tanks are aluminium welded.

However I wouldn't weld a point that is so likely to suffer heat stress.

There nothing fundamentally wrong with core plugs - they've been used for years all over the place.
As long as they are the right size and material. The holes *should* be slightly tapered in doing they do work loose they should have the tendancy to pop out than in.
(my dad use a wooden dowel as a temp repair job once)
Ones with the top hat are probably as far as you'd want to go.

[Eashan]

Heres some pics

[ROY]

Nice job Eashan

[Dave_M]

That does look neat and completely removes any risk of the engine ingesting a core plug. I'd be worried however that the heat from welding could distort the manifold's mounting face, making it impossible to get an airtight seal.

Dave