andybp Posted December 19, 2017 Author Share Posted December 19, 2017 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: 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 Quote Link to comment Share on other sites More sharing options...
Jay84 Posted December 20, 2017 Share Posted December 20, 2017 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. Quote Link to comment Share on other sites More sharing options...
andybp Posted December 20, 2017 Author Share Posted December 20, 2017 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 1 Quote Link to comment Share on other sites More sharing options...
Jay84 Posted December 20, 2017 Share Posted December 20, 2017 And I'm all for aesthetics 1 Quote Link to comment Share on other sites More sharing options...
Titan2782 Posted December 20, 2017 Share Posted December 20, 2017 I think the horseshoe is a good idea as it would provide additional volume since there is no plenum. Quote Link to comment Share on other sites More sharing options...
Dracostan Posted December 20, 2017 Share Posted December 20, 2017 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: 1 Quote Link to comment Share on other sites More sharing options...
Rocket_Rabbit Posted December 24, 2017 Share Posted December 24, 2017 On 12/20/2017 at 19:35, Dracostan said: 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: 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 Quote Link to comment Share on other sites More sharing options...
andybp Posted December 24, 2017 Author Share Posted December 24, 2017 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. 2 Quote Link to comment Share on other sites More sharing options...
Carbon.Ninja Posted January 2, 2018 Share Posted January 2, 2018 (edited) @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 January 2, 2018 by Carbon.Ninja 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted January 14, 2018 Author Share Posted January 14, 2018 (edited) 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 And this is the actual one I will be using so far the time taken to machine this piece is about 4 hours I estimate about another 25 -30 hrs to finish Edited January 14, 2018 by andybp 2 Quote Link to comment Share on other sites More sharing options...
andybp Posted January 14, 2018 Author Share Posted January 14, 2018 If you drag photo's in but don't use them it shows them anyway and won't let you delete them ....Bloody annoying Quote Link to comment Share on other sites More sharing options...
andybp Posted January 17, 2018 Author Share Posted January 17, 2018 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 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted January 17, 2018 Share Posted January 17, 2018 Hang in there mate 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted January 19, 2018 Author Share Posted January 19, 2018 I'm on schedule so far and no F*!* ups and I'm hoping to get quite a bit done this weekend unless the missus has plans for my time 1 Quote Link to comment Share on other sites More sharing options...
gsexr Posted January 19, 2018 Share Posted January 19, 2018 Loving it so keep it coming 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted January 20, 2018 Author Share Posted January 20, 2018 I'm making progress today but it's very slow going due to the limitations of my milling machine but I'll just have to be patient 2 Quote Link to comment Share on other sites More sharing options...
reeceybeaney Posted January 20, 2018 Share Posted January 20, 2018 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! 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted January 20, 2018 Share Posted January 20, 2018 Ahh but its coming along 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted January 20, 2018 Author Share Posted January 20, 2018 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 ? Quote Link to comment Share on other sites More sharing options...
reeceybeaney Posted January 20, 2018 Share Posted January 20, 2018 6 minutes ago, andybp said: Ok I'm going to go for looking dumb what's half cnc ? Well looks open and probably programmable as you've been circular interpolating in the ports, jealous I don't have something like that in my shed 1 Quote Link to comment Share on other sites More sharing options...
reeceybeaney Posted January 20, 2018 Share Posted January 20, 2018 My "beast" at the moment wish i had some inspiration to make something for the z 2 Quote Link to comment Share on other sites More sharing options...
andybp Posted January 20, 2018 Author Share Posted January 20, 2018 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. Quote Link to comment Share on other sites More sharing options...
reeceybeaney Posted January 20, 2018 Share Posted January 20, 2018 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 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted January 21, 2018 Share Posted January 21, 2018 I only have a old milling machine I have to do everything with manual inputs Managed this though Not perfect but close enough. 1 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted January 21, 2018 Share Posted January 21, 2018 1 hour ago, Keyser said: I only have a old milling machine I have to do everything with manual inputs Managed this though Not perfect but close enough. Hip flask holder? 1 Quote Link to comment Share on other sites More sharing options...
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