PanZZer - Check out a hobby store for the stuff guys use for scenery on their model railroads. Hardshell something? I don't think it shrinks like plaster o paris but looks and mixes the same.

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1981 300TD "The Green Lantern"
1980 300TD
1983 300D Euro "China Cat"

Thank you for the tip, After talking more with the foundry guys it looks like my sceme of casting in a plaster mold -they will not do because -they have been there done that, and even the 5th runner alone would require many multi piece shapes to make the sand molds of. They also said other shops would probably do it but-parts never come out right from their experience. So im doing it the "regular" way and heading back to the boneyard to find suitable runner material---I already snagged some that would work on the later 621 intake with the d ports---off the other bimmer cars with the efi inline 6 cyl, No 1 runner works with a little work and i might sell that intake and 5th runner to anyone else thinking of an intake like this--with a lateral flow A/W intercooler.
Now I need to find some the right radius that will end up as 1 1/2 tubes when this particular intake is done---Those early pontoon intakes are HARD to find.

Iits very easy to get set bends in aluminum tubing -But very hard to get continuous bent radius's.
looks like all the promising stuff is japaneezzium. the 240sx has some the right curve and last a 16 valve nissan bottom section either #1 or 4 runners and these are 1 1/2. The port stub off a N'a 300d intake is the d shape and tranzing to the bigger round tube is just a matter of getting it located in the most advantagous spot and filling the step area's with aluminum weld and break out the die grinders and smooth the tranzition.
As far as this guine pig engine there will be a Reel expensive injection pump,the intake tract will be approx 1 1/2" from the plenum to the backs of the valves. The exhaust side will be opend up too and run out to a holset BFT, or if they arrive one of the new smaller ones ala 4.5, but Im sure the vgt controller on those will be a pc board/removable eeprom like the 07 up dodges have.

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