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diy individual throttle bodies


andybp

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22 hours ago, Dracostan said:

Yeah, the flanges would be CNC, but I figure I should be able to find the 40mm & 60mm stainless tube in pre-bent sections and straights and weld it up from that. Getting the 40mm tubes squared off to match the intake port shape is the bigger issue though.

The full piece:

5a383e8ad88c3_VPlenumIntakeAssembly.thumb.JPG.541978d11dd8631c1730c5fe99dbad48.JPG

 

I do have a 3D printer, but as the bed size is only 140x140, I think I will have to settle for a miniature of it for inspiration!

I like it , looks cool but I think it will be hard to fabricate and make it look good but I hope you do B)

:)

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I'm always eager for a lesson, so hear is my question: @Dracostan, isn't the rear horseshoe section redundant? Will having that add anything besides the obviously beautiful aesthetics? Not sure how it would work in regards to available space at the inlet, but I'd rotate each inlet pipe towards the front a few degrees because in my mind that would create less turbulence and a free-er/smoother air flow into each cylinder. But I assume this couldn't be done without the pipe work fouling with the cylinder in front. 

Like I said I'm happy to be corrected and learn stuff.

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31 minutes ago, Jay84 said:

I'm always eager for a lesson, so hear is my question: @Dracostan, isn't the rear horseshoe section redundant? Will having that add anything besides the obviously beautiful aesthetics? Not sure how it would work in regards to available space at the inlet, but I'd rotate each inlet pipe towards the front a few degrees because in my mind that would create less turbulence and a free-er/smoother air flow into each cylinder. But I assume this couldn't be done without the pipe work fouling with the cylinder in front. 

Like I said I'm happy to be corrected and learn stuff.

I think the aesthetics are a good enough reason B)

:)

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Indeed, the horseshoe is for additional volume. I think it will also help balance the draw for the rear cylinders, but that's really a bit of 'finger-in-the-air' fluid dynamics !  The CAD s/w I have does have fluid flow simulation, so I can see what the airflow paths will be - I should be able to simulate draw on each individual inlet port too, so I won't be going at it completely blind.

I did think about angling the intake pipes to the airflow, but the space available on top of the engine is a bit restricted by the rear bulkhead of the bay and the cam covers at the front, so I have only a short distance to fit them.

I also have a 'W' shaped version that gives more volume and keeps the throttle bodies in the 'OEM position' in the bay, but I don't think it looks as good as the V one:

5a3abb2256be8_WPlenumIntakeAssembly.JPG.256983e057cbc6bf5bd89894cedeeeb9.JPG


 

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6 hours ago, Rocket_Rabbit said:

Yeah this is going to lose you performance over the OEM intake.  Each pulse is going to negatively affect the flow backwards and forwards per fire - it'll be like shaking a milkshake!  There is a reason plenums are used - it's cos they work :)

Maybe but the only real way to find out is for him to pull his finger out and build it.

:)

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  • 2 weeks later...

@Dracostan hats off to you (and @andybp as well) for building your own total respect. Thank you for interesting read. 

 

Just sharing my own 2p on the SW.  Generally it is a good package all round, it is straight forward to use compare to other packages I have used.  For the analytic tools I would suggest have a search for more specialised tool.  As I know from the industry they tends to use other software for fluid flow and hardcore FEA.  There are also acoustic tuning software good for engine simulation like Ricardo, may help . :)

 

The experts get it wrong as well with digital simulations.  As it is as good as the person setting the study up and it can spill out complete beans.  It takes a lot of physical test and correlations to get it right.

 

I wish both of you good luck and keep up the good work. More than happy to help although my SW is well dated!

Edited by Carbon.Ninja
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  • 2 weeks later...

Even though I've had a bad case of man flu this build has been progressing though most of the work has been done sat in front of my computer trying to cut 3d ports on a 3 Axis milling machine is hard work

I've also been cutting some test holes before the main event as the large chunk of ally I will be machining isn't cheap

This is the test piece

IMG_20171219_175146.jpg.631b25b4810f0a7f95f516895443786f.jpg

 

IMG_20180114_140934.jpg.f8f8bc5cb8ac53eaa6b6d91373c0dda5.jpg

 

And this is the actual one I will be using

 

IMG_20180114_114850.jpg.95f8e690b3dd1bfe036aae66eed6540b.jpg

IMG_20180114_140625.jpg.848ef9ad953192faaa279213bec73318.jpgIMG_20180114_161158.jpg.30f0857f6d54a4d9e275621ececc3f51.jpg

 

so far the time taken to machine this piece is about 4 hours I estimate about another 25 -30 hrs to finish 

:)

 

 

 

 

 

IMG_20180114_114928.jpg

IMG_20171219_175214.jpg

IMG_20171219_175134.jpg

IMG_20180114_161145.jpg

IMG_20180114_144638.jpg

Edited by andybp
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IMG_20180117_190501.jpg.44d1e688c3dcfcfb490eeecb6b1c4f64.jpg

Each port is taking about 3 hrs to cut so I've been starting one off when I get home and it's finished just in time for dinner, 2 more on the bottom then machine an angle on both sides and 3 more ports on each side so at this rate it will be finished next weekend as long as I don't mess it up, if I do then I may give up I'm not sure even I have the patience to start again :)

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4 hours ago, reeceybeaney said:

Been following this since the start! I'm guessing your mill is half cnc? I'm a cnc machinist myself and it's good to see someone doing some machining for their Z! 

Ok I'm going to go for looking dumb what's half cnc ? ;)

:)

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The real limitation on mine is the stepper motors are too small I ended up using the ones off the previous machine I built ' the problem is if I change them I also need to change the drivers and adapters I made which will probably cost me about £250 -300 per axis and a big chunk of time, so the best part of £1000 and to be honest it's not the money it's the time I've got other things I want to do.:)

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11 minutes ago, andybp said:

The real limitation on mine is the stepper motors are too small I ended up using the ones off the previous machine I built ' the problem is if I change them I also need to change the drivers and adapters I made which will probably cost me about £250 -300 per axis and a big chunk of time, so the best part of £1000 and to be honest it's not the money it's the time I've got other things I want to do.:)

It's still a cool bit of kit to have at home! :) will definitely keep an eye on how you're getting on :thumbs:

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2 hours ago, Keyser said:

I only have a old milling machine I have to do everything with manual inputs :(

 

Managed this though :)

IMG_1111.JPG.b55485fa2261b6c0a5892cec48836856.JPG

 

 

Not perfect but close enough.

Now your machine converted to CNC that would be good ;)

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