Intake Manifold

 
     

The Sidewinder Big Hoss performance intake manifold was designed by Gale Bank Engineering to increase airflow to the Cummins 5.9L turbo diesel.

Bob Robe uses his years of experience to imagine the perfect new intake manifold for the 24-valve Cummins.

Replacing the original Cummins intake manifold with the Banks Big Hoss intake greatly improves airflow to the modified cylinder head.

A complete intake manifold system has been fabricated for the turbocharger on the Sidewinder Cummins compression ignition engine. The system is completely custom to accommodate the large turbo in the tight confines of the Dakota engine bay while achieving optimum flow characteristics. After the stock cast iron air box is cut from the cylinder head and the intake port surface is machined flat, the new, high-flowing Big Hoss intake manifold replaces it. Cast from aluminum, the manifold is designed to withstand high pressures and the hostile environment under the hood.
 

Click thumbnails for larger image
Final Big Hoss performance intake manifold design plans were transferred to a CNC milling machine for machining the Big Hoss manifold castings for Project Sidewinder.

Putting finishing touches on the drawings before they are transferred to the computer.

The cast aluminum Big Hoss performance intake manifold is only usable with a Banks modified Big Hoss Cummins cylinder head.
 After wood patterns were made from Robe's drawings, each new Big Hoss Manifold is cast in aluminum. This is a raw casting.
Writing the Big Hoss performance intake manifold machining program is a time consuming process. When finished, actual machining will be very fast.
 Shawn Collins transfers the finished drawings to the computer and writes the CNC instructions.
For increased diesel performance from the Cummins compression ignition engine, the airbox was removed from the Cummins cylinder head and replaced with the Big Hoss performance intake manifold on Project Sidewinder.
 Then each casting is CNC machined, in house, from Shawn's computer instructions.
The Banks Cummins Big Hoss performance intake manifold fits neatly into the Project Sidewinder engine compartment.
This is the Banks Big Hoss in place on the Cummins 24-valve with the new electronically controlled common rail fuel delivery system in place and plumbed to the cylinders.