I was just talking about casting the manifold, it would be kinda heavy if I milled it. But yes I intend to to do just what you are suggesting. I am hoping this hobby is more complex and challanging than I ever imagined. If I thought it were something I could master in 5 years I wouldn't bother with it. I know I'm talking big and asking dumb questions, but how exciting would the prospect be if I were dreaming about milling aluminum key chains? Quite honestly I don't care if my first engine siezes up or falls apart (safty concerns notwithstanding) I'm interested in learning and comming up with new ideas and trying things that others think are stupid. That is how innovations come into being. How many brilliant inventions were dreamed up by big corperations following the rules and taking baby steps? NONE! To answer your question I'll probably do materials analysis after a few failed attempts at guess work. Will that bother you? This is a hobby, my intentions are to have fun and to learn. Why is everyone so concerned that I won't do it right the first time? Who the hell ever does? One guy says get the biggest lathe you can and another says get a mini one to learn on. I'm pretty sure I can learn just as well on a large one and from what I've seen on ebay it won't really cost me much more(I have friends with large trucks that will haul stuff as far as I like and I just have to pay for time and fuel so that''s not an issue. I think I'll start with a mill and a lathe and an assortment of accessories, and just start messing around. I've downloaded an assortment of books to read in the mean time to get some beginner project ideas. I'm just posting my engine design to keep ocupied for now. Why does everyone keep talking about "years of practice and experience" like they are a terrible thing that I can't afford? If I make my first working engine in 20 years I'll be ecstatic! Chill out and just humor me for Pete's sake.