Cut the runners with a ban saw.
Cut down the center of the pipe with ban saw.
Used a cutoff wheel to cut along the curves of the ubend (11ga 4in), i just used a sharpie and traced the mandrel lines and followed those. You can actually get a decent cut if you allow the saw to drag your hand, and just steer it in the right direction. Then i tacked them to the flange.
Once i had them welded i laid the plennum on the piece of sheet metal, and traced it. Then cut it out with the cutoff wheel. I gave myself a lot of leeway when cutting, then shaved down bit by bit with the flap wheel, checking every time until i got the fit i wanted.
Realizations that helped me grasp how to weld/ tac aluminum. Tacking was the hardest part for me, once i realized that you had to start on the thickest piece, move the puddle over to the thin metal and dab the filler it was all downhill from there. Its really cool when moving the torch, to watch the thicker piece just melt the thin. Then you just dab the filler and you got a strong tac. Once you actually get the bead started its just about filling the "weld vagina" with your "rod" and dragging/ pushing it along with the torch. You can watch as one side slows down or speeds up to see which piece you need to direct heat at. And you also watch the width to see how much penetration you're getting/ how much you want. Still have much to learn and need to get better consistency, but the welds should be plenty sufficient for what i need them for.
Unfortunately i was in a time crunch and the car i was fitting the manifold up on (Slow Ka-t's) did not have a hood. I underestimated the angle of the runners, and upon finishing everything but the TB elbow i realized there is no way it would clear. all it would need is more angle on the runners and it would be fine. I really wanna thank nick (twinturboz) for the use of the welder and SloKa-t for letting me mock it up on his car and many other random inconveniences he had to deal with with me walking in and out of his garage/using his drill press/air grinder longer than any man rightfully should. Love both your wieners. Even though it dosnt clear its a great experience for me to learn, and gives me much more freedom with my car.
When I find someone in North Carolina with a welder and the right tools i will redo the plennum. Im looking for a cheap head flange option so i can do oval/ circular runners and injector bungs. Im kinda tired of dealing with the **** of stock upper plennum (butterfly valves, plugging ****, etc,). Any suggestion on head flanges lmk. Thanks for lookin.
. My whole thing with my car is to always keep it so if i wanted to go back to stock i could, i like to keep the feel of a street car with it. IE Full interior, power steering, nice and quite on the inside, yet still handles and pulls good. There's enough 240's with mutilated interiors and cut up everything. Ima redo it better next time. It'll be a lot simpler and make all my effort worth more skrilla with actual runners and possibly velocity stacks if im a cool mofo. 
