Intake Design and Building: How to?

Mr_Asa said:

Gluing session.  Fumes are fun.
I'm going to need to do some post-processing after this, the printer is definitely not liking the strain I'm putting it through.

 

 

 

 

Did you split up the model in CAD or is there a slicer trick to do that?

Split it up in CAD.  There might be a slicer out there that allows you to do that, but I haven't run into it.

Just to be sure....shrinkage and miss alignment have been factored in?

I'd expect that the casting is going to shrink considerably from the mold/at time of pour. I'd also be under sizing the flanges in anticipation of a shift or minor miss alignment so that it can be port matched for proper fit.

Mr_Asa said:

holy crap thats a lot of tabs

Mr_Asa said:

Split it up in CAD.  There might be a slicer out there that allows you to do that, but I haven't run into it.

Thanks.  I was hoping that there was a slicer add on or something that I haven't run into.

In reply to ProDarwin :

I over-tab when doing research.  I've got four or five windows open right now with not quite that many tabs on them.

Gotta find the add-ons that temporarily kill chrome tabs that aren't actively being used.

asphalt_gundam said:

Just to be sure....shrinkage and miss alignment have been factored in?

I'd expect that the casting is going to shrink considerably from the mold/at time of pour. I'd also be under sizing the flanges in anticipation of a shift or minor miss alignment so that it can be port matched for proper fit.

From my experiences, and reference books, 5% is common on Aluminum.  I haven't cast anything this big before, but thats what I'm aiming for.  If it gives me problems I can do some surgery.  If it is real bad I can just cut it up and start over.

Mr_Asa said:

In reply to ProDarwin :

Gotta find the add-ons that temporarily kill chrome tabs that aren't actively being used.

I've noticed that recent versions do that by default now. I blame people like you! ;)

In reply to obsolete :

It's only taking up 70% of my current available memory.  No big deal

I don't know how you tab people function. I can't even keep more than a dozen emails in my spam folder. 

In reply to maschinenbau :

Big ADHD energy, over here. 
I've got four or five books I'm reading right now, the tabs come from that honestly.  Hell, I remember getting in trouble in English class in high school for reading during class.  Teacher took my book, gave it back at the end of class.  Next day I brought in all the books I was reading.  She'd take one, I'd start reading the next.  Process repeated a few times.

Just noting that now my casting materials will be listed as "free."  Anyone know what that wheel is from? Lots of German on it

GRM: Home of Stewards of The Earth.

BMW

Style 79s. E46 wheel I think

Can confirm BMW, I found a sticker on the strut.

In reply to Mr_Asa :

So what happened

Hell if I know.  Best answer I can give is "Its I-75."  Everyone on it is a berkeleying moron, including me for being on it.

I just saw it and had a gap in traffic so I pulled over.  Now I have aluminum for melting down and casting that I don't have to pay for.

I don't know how I missed this all till today, but awesome!

Have you done the calculation on the length of runners?  I was using this for the length based off a lower revving setup.  My harmonics number is probably off, which could really affect this too.  Also, this is from the valve to the end of the runner. 

<Runner length (mm)=((Speed of Sound in air @ IAT (m/s)*1000)/(2*Harmonic wave))*((60/RPM)/360)*Cam Duration @ .050>

(323*1000)/(2*30000)(60/3500/360)(192) =

I got about 625mm or 24"

I dont know if you were more planning on a different Cam, RPM range, and all that.  Also, Harmonics is a bigger question.

As I've said elsewhere, I've been moving towards just whipping this out so I can throw it on the truck instead of a still theoretical Challenge build, which means less casting, more sheet metal fab.  So now I'm trying to figure out a good way to shape circular runners into cathedral ports.  I'm thinking another 3D print will come into play here.  SendCutSend.com will also probably come into it.
I'm also looking into air horns/trumpets/thingies for the intake, like the below.

In reply to Thinkkker :

I haven't really messed with the intake length calcs.  I've been reading up on it when I can.

Last post 7.5 hrs ago.

Been busy

Round stock, vice/pressed to flatten and lightly ported to fit. 

In reply to Paul_VR6 (Forum Supporter) :

3D printed male and female dies, actually.  Should be somewhat more accurate. 

In reply to Mr_Asa :

quick and dirty is flattening tubing in a vice and pinching it a little for the top of the port, make it a little smaller than the actual port entry and dont worry about it. Im pretty sure going smaller to bigger suddenly is better than going bigger to smaller suddenly for air flow. Dont want the air to hit a wall at the flange because the intake runner is slightly larger than the flange.

Better but more work would be to cast a die. Female part would be round at the base like the tubing and taper into your port shape. The you press the male part in which would be cone shaped and slowly taper to the port shape. I think earlier you mentioned you could do smaller castings yourself. This would be too hard to 3d print and cast, you just need to cast it once then you have the die to punch of 6 runners.

Just thought of a middle ground. Bye the ICT cathedral port intake flanges and use them as a dye. punch some tubing through and shape them by hand. Wont be as accurate and repeatable as a male and female die, but probably get you decent results and you dont have to spend the time casting something.

Or you buy the Chinese LS1 sheetmetal intake off ebay. I think they were like 400 last time I looked. Cut it up and use the runners and flanges (both intake and TB) and weld you plenum on it and your done.

Irrationally happy right now.

Also, they sent me a couple Sour Patch Kids.

Not 100% what I wanted, but not a bad result either.

I fear I might need to go to a thinner wall, and if I do that I'll lose some strength.

Looks like its coming along nicely.