I am using 90 degree angle silicone elbows instead of the 45s

I found the 45s not doing the job. I bought a skunk 2 header off of some kid on craigslist and chopped it up. The skunk 2 runners are seperated and allow you to fit fit the hoses/clamps in there easier. Also the manifold is slightly lighter.

As for how much to cut.. I cut my runners to where there was 1" of metal for the hoses to grip onto on the flange side. Then shaved a little at a time on the upper piece. When you are done taper all of the ports and polish them. On a D16z6 with very little mods I received a pleasant 120hp at the wheels.

I did have a one piece intake welded a long time ago but it formed many vacume leaks at pin holes at the welds. The welder did a S***.t.y job and I went with the elbow route instead.

Did you raise the fuel rail higher then it typically is? It seems it? If so how did you raise the injectors etc?

This project is coming along good..I only work on it a little here and there,just started after the winter again.

Since you didn't specify which motor you have, I'll just assume you went the best route with a D-Series. 

This is what I eventually did with mine. I assume a B-Series could be done similarly.

Good opening line. You're sure to get a 'ration' from the cost-and-skills-are-no-object folks.

Have you considered asking BJ for a reccomendation based on their current experience?

 The orange "Dean's Mini" on their site uses a Skunk2 intake.

BUT I'm giving it a try,they had switched to 90 degree bends,does anyone have any pictures? Did you CUT the intake only...or remove a section,and if so how much? I am using the SKUNK 2 and have the two master cylinders on the driver side /LHD car.

I'm noticing the way I have it there isn't much room for the fuel regulator..any pics and info of how ypu guys did it? Thanks