Boss 302 Inline Carburetor System Lost Foam Casting 

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!

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

Absolutely fantastic my friend!!!

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.

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!

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.

Thank you making such detail videos.

That Autolite inline four is worth a ton of money.

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! 👍😎

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

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

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

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

very inspiring and motivating God bless

magic man, pure magic

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!

Awesome as always! Greetings from New Zealand.

WOW I am impressed

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

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

Work of art man.

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 👍

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

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!

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

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).

Beautiful work.

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

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.

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

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

Amazing work as always, thank you for sharing!

Amazing. Love watching these videos.

Pro level here

I was very impressed with your work...

Amazing!

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

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

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!

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.

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.

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..

Beautiful!

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.

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

Oustanding

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

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

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.

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

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 😅

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?

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

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

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

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

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

Can you get the inline autolite carburetors

Is are those used to made sandmold?

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

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!

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!

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

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

What brand smelting furnace do you use?

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

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

Do you ever do lowers?

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

I'll take 4 please..😊

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