Pete Gossett
Pete Gossett MegaDork
2/8/18 6:08 a.m.

In reply to corsepervita :

Wow, awesome job! It still amazes me you can make stuff like this at home for a relatively low investment. Unfortunately, I would never ever have the patience to deal with that - let alone take the time to learn CAD. 

corsepervita
corsepervita HalfDork
2/8/18 12:04 p.m.
Pete Gossett said:

In reply to corsepervita :

Wow, awesome job! It still amazes me you can make stuff like this at home for a relatively low investment. Unfortunately, I would never ever have the patience to deal with that - let alone take the time to learn CAD. 

Currently I'm using google sketchup and rhino 3d.  I bought a license for Rhino years ago when I was in college (literally a decade ago).  The software still exports STL files (which are used in 3d printing), and so I can do the more fine and weird precise stuff in skectchup and move things over for the fine 3d perfection in rhino.  Toss it into cura, and boom, print.

 

Once it got mostly calibrated it was much easier.

RevRico
RevRico UltraDork
2/8/18 12:22 p.m.

What printer did you go with? You are using ABS or another higher heat filament for in the vehicle instead of PLA, right?

I don't think I've chimed in at all on this thread, just been watching from afar trying to wrap my head around things. Fantastic project for a great car, and seeing everything come together has been awesome. Bonus awesome by going straight to WSJ too. 

corsepervita
corsepervita HalfDork
2/8/18 12:59 p.m.
RevRico said:

What printer did you go with? You are using ABS or another higher heat filament for in the vehicle instead of PLA, right?

I don't think I've chimed in at all on this thread, just been watching from afar trying to wrap my head around things. Fantastic project for a great car, and seeing everything come together has been awesome. Bonus awesome by going straight to WSJ too. 

I am actually using PLA right now.  I'm using a maker select v2.  I'll snag pics when I get home.

corsepervita
corsepervita HalfDork
3/1/18 2:07 a.m.

So the velocity stacks from the original 42mm DCNF webers are a flow killer since they don't match.  Been working this week on making some that I can print out.  After that i'll print out some air boxes.

These are 40mm, with a 7 degree peak at the top, then used some bends and flares to make a nice round bit at the top and merged them.  Should be a nice improvement.

corsepervita
corsepervita HalfDork
4/22/18 2:11 a.m.

Well guys.  Life has been a bit... uhhhh, crazy.

I quit my job that was making me miserable.  Found a new job.  I've also been busy as hell working on velocity stacks.  Happy to say my first set has finally gone from 7 different revisions to what you see here.  They're on the lambo and happy as a clam.

I need some more mounting hardware that's prettier but this was just for testing.  Best part is they'll fit DCNF webers and DCNF style ITBs, so i'm stoked about that.

I got the lambo put back on for full time insurance so i can scoot it around and have fun.  I don't have a lot of time since the new job is nuts.  I've slept maybe a total of 12 hours this week, but it's the best thing I've ever done and I love it.  I'm finally sleeping this weekend so that's rad.  I need to flow test and re-sync my itbs now that these are on.  But the response seems much happier, and since there's no more lip there's no more flow killers!  They're perfectly matched to 40mm, printed at 100 microns.

Jerry From LA
Jerry From LA SuperDork
4/26/18 7:24 p.m.

I wonder if the ridge-iness impedes airflow or enhances it.

 

Recon1342
Recon1342 Reader
4/26/18 8:39 p.m.

In reply to Jerry From LA :

The rough texture should disturb the boundary layer air and help accelerate airflow more efficiently.

AngryCorvair
AngryCorvair MegaDork
4/27/18 9:58 a.m.

In reply to corsepervita :

i bet there's a market for those stacks.  can the printer run while you sleep?   because getting paid to sleep would be my dream job.

Jerry From LA
Jerry From LA SuperDork
4/27/18 1:10 p.m.
AngryCorvair said:

In reply to corsepervita :

i bet there's a market for those stacks.  can the printer run while you sleep?   because getting paid to sleep would be my dream job.

If you can print brake pads, then your dream is a reality.

corsepervita
corsepervita HalfDork
4/29/18 10:31 p.m.
AngryCorvair said:

In reply to corsepervita :

i bet there's a market for those stacks.  can the printer run while you sleep?   because getting paid to sleep would be my dream job.

mezzazine has already bought a set from me ;)  i can easily set it up and walk away and come back to parts.  The only part that sucks is that i print at 100 microns for good quality, so it takes forever.  I'm planning on buying another printer for larger parts here very soon, and will have them both running nonstop.

Jerry From LA said:
AngryCorvair said:

In reply to corsepervita :

i bet there's a market for those stacks.  can the printer run while you sleep?   because getting paid to sleep would be my dream job.

If you can print brake pads, then your dream is a reality.

I mean I could but I'd feel bad for the poor chap who was like, "It stopped great for about 2 stops and then it just smelled like burning plastic and all I smelled was hot plastic and metal" frown

corsepervita
corsepervita HalfDork
4/29/18 10:36 p.m.

Alright so ... my brain hurts but i've been working on a design for my air plenums and these are nowhere near finished but i've got a mini sketchup in rhino of what i want them to look like.  The complexity in rhino wasn't good enough or efficient enough so i'm now working on them in google sketchup.  My first prototypes will be multiple pieces because of the fact my printer can't print any one piece this big.  Once I get a bigger printer? No problem.

All i've really got is a set of digital calipers so it's a LOT of measuring.  I derived the dimensions by measuring the stock airboxes, the thickness of the aluminum, where the ITBs would sit.  Where they currently sit on the runners, subtracted that top to bottom vs the top of the airboxes and calculated my maximum height from there.  Then measured width of the airboxes where the actual linkage would NOT be on the stock airboxes (because that's a thing).  This is what I've got so far.

The next steps will be to extrude some small areas in there so I can put something to seal between them and design some stuff on the sides where I can put something to retain them.  I kinda like the oldschool clamp style stuff that Porsche used on their airboxes, but I've also though of going 911 style rubber straps from side to side since that's also pretty efficient.  I need to measure the straps on my 931 and hunt down some hardware.  I do NOT want to do screws because I want something that's super easy to just get into on a whim and access.

Once I've got them in halves with that down I can figure out how I want to do the air outlets, which i'm thinking of just extruding in a similar manner to the rhino sketchup I did.

Current mood music for sketchup

 

KaiserM715
KaiserM715 New Reader
5/25/18 1:55 p.m.
The0retical said:

In reply to corsepervita:

That would be hilarious actually. The best machining and casting techniques that Italy had to offer in the 80s gets worked over 30 years later by a group of people that that consider used craigslist appliance sheet metal to be the best source of NLA body panels.

Still getting caught up, but this quote is worth a revisit.  Indeed.

 

Awesome project and one of my favorites on GRM.

corsepervita
corsepervita HalfDork
7/30/18 10:27 p.m.

I know it's been a while since i've posted an update but ...Work has been insanely busy, and even tonight I've gotta get back to it, but I wanted to share the progress of the airboxes, which are ready to print.

At high quality, 100 microns, it's going to take roughly 14 to 18 hours for each piece.  Should have it on the car by the end of the week if I time it right.  Can't wait to see the first one on the car.  Finally can have some airboxes to fight the heat of the engine bay!

Rufledt
Rufledt UberDork
7/30/18 10:32 p.m.

that is most excellent, can't wait to see how it works

lnlogauge
lnlogauge Reader
7/31/18 8:55 a.m.

I have an issue with printing radiuses like that. It works, they just look like garbage in the end. Cura won't add support brackets, or at least I don't know how to. 

Dou you do anything special with the print?

 

Ram50Ron
Ram50Ron Reader
7/31/18 9:06 a.m.

In reply to lnlogauge :

You need to play with max overhang angle in support settings.

corsepervita
corsepervita HalfDork
7/31/18 11:57 a.m.
lnlogauge said:

I have an issue with printing radiuses like that. It works, they just look like garbage in the end. Cura won't add support brackets, or at least I don't know how to. 

Dou you do anything special with the print?

 

I'll show you a preview of the settings i currently use on my airhorns when i get home.

Jerry From LA
Jerry From LA SuperDork
7/31/18 1:09 p.m.

Hey corse,

Since we have you here, how's it going with the car?

corsepervita
corsepervita HalfDork
7/31/18 1:56 p.m.
Jerry From LA said:

Hey corse,

Since we have you here, how's it going with the car?

It's good! I haven't had too much time to enjoy it lately because work has been absolutely insane.  I've started though with some fritz diagrams for some microcontroller stuff.  Since the ultrasmith on the car was no longer functional, i've also been working on designs to revive it work some modern tech.

Where the previous little led indicators were on the console for a radar detector were, I plan on making a tiny little touch screen with led indicator for things like dash cam recording and some of the old accessories.  I have a spare LCD screen and some leds i can use, and plan on printing out a little plate where that'll go instead.  

Due to lack of time with life due to work these are just having to happen as things go.  Last night though i had a few hours before a software release so i drummed up the rest of the airboxes.

I finished the calibration of getting the GPS unit to work with my car, but i'm hung up on the code to translate that into moving the stepper motor.  If I put in a fake value, the stepper motor goes where i want it.  And somehow pulling the variable and slapping that into something that'll move the stepper has me hung up.  So the speedo is almost done, just... blah.

If there's any fellow arduino geeks on here that are good with that, i'd be happy to share the code to see if we can figure it out.

T.J.
T.J. MegaDork
7/31/18 2:42 p.m.

Are your velocity stacks and airbox printed out of PLA? Won't it get too hot for PLA in the engine bay? Seems like a different filament would make sense for things in the engine bay. Heck, even your window switch plate might not like it if you park the car with the windows up in the sun on a summer's day.

T.J.
T.J. MegaDork
7/31/18 2:43 p.m.

In reply to corsepervita :

There are some arduino folks here. If they don't pop into this thread, just make a separate topic and they will find you.

corsepervita
corsepervita HalfDork
7/31/18 3:00 p.m.
T.J. said:

Are your velocity stacks and airbox printed out of PLA? Won't it get too hot for PLA in the engine bay? Seems like a different filament would make sense for things in the engine bay. Heck, even your window switch plate might not like it if you park the car with the windows up in the sun on a summer's day.

They are.  But PLA begins to melt at about 190C, if my engine bay is seeing temps that hot, i'm far more concerned about my aluminum heads.  We'll see how it holds up, worst case if it doesn't hold up the way i expect it to, i'll change to another filament.  But I don't think it'll get so hot that it warps like that.  Filament is cheap anyway, so if that happens no big deal, I'll print something else.  

I should note i've been driving around with open itbs in PLA for a little while now and i've had zero issues so far.

Matthew Kennedy
Matthew Kennedy Reader
7/31/18 9:22 p.m.

In reply to corsepervita :

Is your code shared anywhere online?  Get that stuff on Github!

T.J.
T.J. MegaDork
7/31/18 9:33 p.m.

In reply to corsepervita :

Sounds like a plan. I thought PLA started getting soft at 140F or so, but if it works, it works.  If the plastic got soft and gooey from the heat it would suck if some part of it ended up in a cylinder.

I love that you designed and printed your own velocity stacks. Well done!

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