Well, as you've seen I've been tinkering with this idea (and some others). But really out of shear selfish necessity I needed to make it a reality. So I did.

- I need a couple intakes with the stock offset.
- I'm not paying $130+ for one I don't like, nor $160 for one that won't work, nor $50-$80 for someone's used and petrified original intake.
- I want options for different carbs, particularly larger ones.
- I want to run the stock airbox with slight modifications at most (when using larger carbs).
- And I don't want to have to shell out $100+ if the boot tears for whatever reason.
- I'm not looking to get rich off of this little project, but I do require a fair kick-back for my investment of time and money.

This is my answer -- I call it the FL350R Intake Dan-i-fold.

The design is based on the stock intake, but uses a standard aftermarket carb flange with a 70mm mounting bolt spread (or 60mm for 30-34mm carbs). These flanges can be had for $15-$30 brand new and come in a variety of sizes to fit whatever carb you'd like to use (from 28mm up to roughly 40mm). Solid billet 6061 aluminum bar cnc machined by professional machinists at a real machine shop in the USA - not made in my pole barn or someone's damp rice shack in China. Full print dimensional and quality check before they ship to me. There is enough meat on the bone on the outlet side of the manifold to allow the user some port-matching. The output is the same height as the stock reed cage and ~5mm less wide. There are a couple of bosses added on the inlet side so as to prevent any thin-wall conditions as-is and if port-matched and/or opened up.

Stock Keihin PE32 carb -- no modifications required. Bolt on the intake manifold, bolt on the 30-34mm carb flange, and run down the trail without worry. Same bolts, same reed cage, same gasket.

Larger carbs -- I've bolted on the Keihin PJ36, Mikuni TM38, and Keihin PWK39 A/S with the stock airbox in place and without carb / trans mount clearance issues. BUT but but...running a larger carb requires an aftermarket rubber elbow and a couple of custom PVC fittings that fit right to the stock airbox with no cutting or molesting required. The problem is that the stock inlet tube from the airbox will only fit the stock carb's inlet side. And as long as your inlet tube isn't too fossilized, you can boil it and fit it over a Mikuni TM34. I prob won't be assembling any "parts kits" for running big carbs, but will likely simply share my ideas & sources of the parts for anyone interested. The inlet tube and couple pieces of hardware are under $15 and requires basic hand-tools.

User will be responsible for jetting their own machine for the carb they choose.

Part has been 3D cad designed by me, enhanced by cnc machinists, rapid prototyped, fitted, quoted, and PO issued for a limited order quantity. Parts are not anodized or treated. This is machined billet 6061.

Check out the pics.

I am offering a limited pre-order to the PO.com community with parts arriving to me on Friday April 11th. PO.com price is $99 + s/h (evilBay price will definitely be higher). Paypal, Cash or Money Order. Ship via USPS Small Flat Rate, FedEx Ground/Home, or local pick-up. Parts ship after payment cleared. Don't know me? I've been on here & everything2stroke.com for a while, a dozen or so members have been to my house, and quite a few know where I work. I'm on LinkedIn and FB. I've got nothing to hide.

PM or email me if interested (danauxter2 at Yahoo dot com). I can add to my order as long as I get the numbers in by Tuesday morning, April 8th, 8am EST.

Included:
(1) billet 6061 manifold
(2) M6x1.0 flanged-head bolts (Fastenal: M6-1.0 x 16mm DIN 6921 Class 10.9 Yellow Zinc Flange Bolt)
(1) full-size scale template of the 6-bolt intake gasket (DIY style)
(1) full-size scale template of a 2-bolt flange gasket if you want to run one (no reason the flange won't seal alone, but some are skeptics)
(1) Mikuni listing of carb flange part #'s and dimensions
*RUBBER CARB FLANGE & CLAMP NOT INCLUDED*
*THE (6) MANIFOLD BOLTS ARE NOT INCLUDED*

Again, this is a limited run. Keeping (5) for myself and sending one to "Mr. H" on the house. If they sell out, I will get more made with pricing and timing based on demand (more is cheaper). The excess will be listed on evilBay.


Many thanks,

Dan A.

More pics...

NOTE: the two flange screws are not the real screws. This is just the prototype. Will include a pair of 8mm flanged hex bolts. Parts may appear dirty int he pics only because I was fitting them on my dirty & grimey Oddy #3.

And some more...

Sweet! Can you list the required bolt sizes and quantity soon as you establish them?

What about the Pilot?

Can you send me the plastic one too never held a 3d printed thing in my hands yet, I can send it back if you like just like to see it up close.

Thanks.

The (2) bolts included will be (EDITED) M8x1.25 flanged-head bolts (Fastenal: M8-1.25 x 16mm DIN 6921 Class 10.9 Yellow Zinc Flange Bolt). They're $0.98 ea from Fastenal.

I'm not lucky enough to own a Pilot yet, so can't really do much there. My motivation was from my four FL350's, well really three since one is Rotax'd. If/when I get the time, I can draft a Pilot one up in 3D and look into it. Just don't have a Pilot to try it out. Cost would be about the same, though.

Sure thing, H, I can send you the p-type on borrow. Its actually hollow. It took 2.5hrs to print. Printing a solid part with fine resolution would've taken an entire day and there is greater likelihood for a file error, power outage, moron bumping the printer station, etc (and I can't afford the cost of a fine-reso p-type! lol). Designed many parts and machines on CAD, but there is nothing....NOTHING like holding your brain child in your hands or watching it operate.

-Dan A.

ALREADY AN UPDATE: Meeting with the machinist tomorrow morning, but just got a message from him (he's on 3rds tonight). The 36-40mm carbs require the carb flange with 70mm hole spread, and the 30-34mm carbs require the carb flange with 60mm hole spread. SO...we may end up putting BOTH 70mm & 60mm spread sets of holes on the part, rotated a few degrees apart. Then the manifold can truly be used for 28-39mm carbs. It wasn't an oversight, just was waiting on a decision of what the cost delta would be to add the second hole set. Was hoping I could dig up a flange that was 70mm for the hole carb range, but didn't. Since its same hole thread and depth, the price delta is pretty much nil. So...actual part may vary a tiny bit, but for the better.

Looking at the Mikuni flange chart, don't be alarmed at the generic Mikuni sizing. I can get a PWK39 in that VM-36-200 boot no problemo. Keihin dims are a little different.

Great looking Dan-i-fold D$. if i was still running stock engines i would have to have one. But just wanted to say thanks for taking a project like this on!

Here is the version that is truly 28-39mm carb capable...

Sorry about that. Would've bet the farm I found some 70mm hole spread flanges for both 30-34 and 36-39 Mikuni sizing. And I would've LOST that farm.

The 70mm holes do peak out from behind the smaller 60mm spread flange, but no worries. The primary seal to the manifold is a raised ring on the back side of the rubber flange.

Way to go Danno.

Would you mind if I posted this on some other sites. The 350 odyssey manifold is a popular upgrade on aircooled atc 250r and 300r for a bigger carb.Thanks DP.

Go for it! I've got about a dozen or so left from the first batch.

How much are they selling for.

$125.49 shipped on eBay. Or if payment can be made privately (avoid fees), price is $104.25 shipped. EBay/PayPal suck up $17-$18 of fees PER ITEM SOLD. So I encourage the private sale.

Powersportsuperstore.com is where I bought my mikuni flange for the M-VM36-200k for about $17.19 shipped. Thought I would share this. Average shipping speed.

Awesome! That's the cheapest I've seen yet!!

Do they come with with the rubber flange or not.

Flange is not included.

FYI...I was selling these WITH the rubber carb adapters. Since I sold out, the adapters have jumped price, too.