My 2.4 Six Engine, Manufacturing prototype intake adapters. Options

[McMark]

I picked up this 2.4 six awhile back and I'm gonna use this thread as I develop the engine which will eventually go in my gold car.

I'm starting a little out of order, but too bad. (IMG:style_emoticons/default/tongue.gif)

So I have this aluminum flywheel. No manufacturer stamps or numbers on it whatsoever. I'm thinking that it might be too light for a street car, so I may not use it. It's about 3lbs by itself. I've got a 914 clutch adapter (basically a cut down 914/4 flywheel that bolts to the outer edge) and that brings the total flywheel weight to about 10lbs.

I want a streetable car, is this thing too light?

[jpnovak]

I hope Mark doesn't mind my response. I am printing the prototypes for him.

I am many have seen/heard about 3D printing. It is a pretty cool process.

The process starts with a 3D CAD file. There are many ways to get one of these but the process involves modeling in a CAD program. The CAD file is then transformed to a "surface" file that is a map of the external surfaces of the part. The printer software then slices this into invidividual layers. These are cross-sections cut to the plane of the base substrate. Its kinda like a stack of Pringles Chips.

Once the software knows what each layer looks at it starts the printing process. The printer is a hot filament extruder. There is a feed stock roll of plastic wire filament. There is a pinch roller and toothed gear that forces the plastic through the hot extruder tip (230 deg C). The tip is then numerically controlled via a standard coordinate system. Its like putting a tube of toothpaste on a XYZ positioning system.

The part prints the inner and outer perimeter first and then fills in the void space with a criss-cross pattern. The density of the fill is adjustable. The grove in the top is a software glitch where two perimeter lines close together do not get adequate fill due to the narrow space between them.

If you look at the part you can see the individual layers that are stacked. This is the concentric surface finish. There are ways to smooth this easily. The pictures just show the raw part off the printer to check for dimensional fit.

I printed these parts in ABS plastic. This does not print as smooth as the other common filament , PLA.

The prototyping process is VERY fast with one of these printers even if the print process is slow. This part took about 3 hours of print time. Material cost is just a few $. The process creates an accurate part for mock up and test fit. It is easy to modify parts without spending a lot of machine time and cost at an outside vendor. Compared to prototyping in a machine shop there is no cost comparison. Cheaper. Faster. Simpler.

PM me if anyone has an interest in having parts made. I have very reasonable rates.

I hope Mark likes the part. I plan to ship it out today.