Hi D, This is only the second, hand formed manifold i have made. I made a 6pack charger manifold to suit 58mm DCOE`s for Group Nc.It was just ridiculous..

I started with a block of hardwood, shaped it by hand and in the milling machine to get the desired shape.
Then cut out the 6061-0 temper ally sheet, screwed and glued it to the block then used a pear shaped mallot to carefully work the two halves around the mould.

Im still learning myself..

I perhaps should have done a step by step with photos for the forum. If i do another one i will..

Yes please even the Wood mold would be nice to view.
Can you tell me what thickness ally plate you used?
The whole forum cant wait till you show us more.

The ally is .100" thick (about2.5mm) And is 6061-0 condition, The "O"ondition is the important bit because this allows the ally to be easily formed. as you work it it gets harder. Once its finished it should be heat treated to get it up to the T6 hardness, probably not critical tho.
For this high boost application i will probably get it done.
I`ll post some pics of the mould soon.