Ok, where to begin.....
Found some more flaws in the casting. This is the worst LIM and SC I've ever worked on. Both of them. Easily. More work to patch up:
Got a little over-zealous on the LIM milling, and found I'd overlooked two tiny cutouts in the SC that I'd milled enough in the LIM to expose (greyhare spotted it this morning) so we have to get creative (this is why God invented the word 'prototype', and why I have more than one or two manifolds and superchargers laying around here). Some of this goof has to do with PCV flow, so it can't be ignored. Some ports shouldn't be exposed to the LIM cavity, and some should.
Let the milling begin. Greyhare (Mike) milled the blockoff oops plates while I milled the SC (we had two mills screaming like little girls at a horror movie for a good hour and a half). He also had to do some delicate corner radius work to match my milling on the pockets:
(greyhare deftly dodging blue flaming hot chips from h e l l)
The back to home, roughing in the outlet and other stuff. The proto plug plates are drilled, countersunk, and back-cut. The SC is back-cut in the corners and below the drilled holes in the plates to bind with the JB better:
the 'step' you see in my milling on the side is due to internal PCV passages that I really didn't feel like milling into tonight.
Quite a bit of finish work to do. We went out between snowstorms today and figure out on the SLE that the routing of the cooling lines will have to change from the plan drastically. More on that later.
Also learned that this isn't going to be as easy on the S2, which sucks considering the investiment so far, as the S2 manifold is MUCH narrower in that big open area between the ports. I can get a much wider core in there than them, but shorter in length.
The other unfortunate part is that while my goal was to make this possible for at least a few S1 L67 owners here, the practicality isn't there. Mine will work, but there'* alot more custom work involved than I'd originally hoped. I hope at least one more S1 tries this, and a S2 or two also.