1) I have been thinking through just how to build the inlet section of the intake manifold and have come up with a working design taking a few different concepts and combining the best features. In the picture you will see the basic components of the inlet mold. These are a collection of schedule 40 PVC couplers (from the Aviation department at Lowes of course) that will form the body of a mold which will represent the inside of the finished part. At the bottom is a 3Ã¢â‚¬Â to 2Ã¢â‚¬Â adapter and above that are two different lengths of 2Ã¢â‚¬Â coupler. A bit of duct tape will join these together rigidly enough and a coating of expanding foam will provide a gently tapered form between the two ends. The last inch at the top will remain at its current outer diameter to form a coupling that can be slipped over the rest of the intake manifold to form a good seal. With the transition section properly formed a coating of wet micro will fill in the porosity and provide a smooth surface for the molded part. A couple coats of mold release wax and a couple of coats of PVA mold release and it is ready to build the inlet. That prep is done everywhere except for the straight section of the adapter at the bottom which will be scuffed up to a provide good bond with the epoxy resin. A few layers of BID should provide a good strong inlet section built up over the mold. The straight section of the adapter will then be cut away from tapered section on the inside (not that easy but doable) and then the tapered mold should be able to be pushed out through the front. After all of that a layer of BID will go over the inside of the PVC section to cover it and lock it into the inlet. By retaining that portion of the PVC I will have a very strong and impact resistant inlet lip which is exposed to the world and all of its hazards.