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> My 2.4 Six Engine, Manufacturing prototype intake adapters.
McMark
post Aug 9 2013, 11:09 PM
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All done an ready to ship to me. (IMG:style_emoticons/default/boldblue.gif)


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euro911
post Aug 10 2013, 01:09 AM
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Cool.

What is the material, Mark?
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jimkelly
post Aug 10 2013, 04:17 AM
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why the groove seen from top? is it a two piece part glued together?

so the printer does not cut material away from a block of material - instead - it builds material up and up and up till a part is done ?
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jpnovak
post Aug 10 2013, 06:18 AM
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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.
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Krieger
post Aug 10 2013, 09:27 AM
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Very cool to see the cutting edge printing edge applied to our cars.
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McMark
post Aug 10 2013, 09:39 AM
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Thanks for chiming in Jamie. I didn't know if you wanted to be identified.

Apparently this ABS plastic is suitable for actually running on the car, but once I have a design that works, I'll be researching aluminum CNC production.
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polo classic
post Aug 22 2013, 02:43 PM
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Did you ever consider using Boxster/997/996 parts, seeing the port spacing is similar, although the water stuff have oval ports

http://forums.pelicanparts.com/porsche-911...rt-spacing.html

http://www.ebay.com/itm/OBX-ITB-INDIVIDUAL...3d8&vxp=mtr

(I know some, if not all OBX parts suck)
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McMark
post Aug 22 2013, 05:23 PM
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Cool! Hadn't seen that. I'd like to try that sometime. (IMG:style_emoticons/default/idea.gif)
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tscrihfield
post Aug 22 2013, 05:37 PM
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This looks very cool! What are you going to have them cast/molded out of?

What is your plan for engine management? (IMG:style_emoticons/default/poke.gif)

Thomas
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McMark
post Aug 22 2013, 06:24 PM
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If the prototype adapters work ill send the CAD files out to mill from billet aluminum.

I'll be using a MegaSquirt system I picked up. Still have to modify it for COP.
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jcd914
post Aug 22 2013, 08:02 PM
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QUOTE(McMark @ Aug 22 2013, 05:24 PM) *

If the prototype adapters work ill send the CAD files out to mill from billet aluminum.

I'll be using a MegaSquirt system I picked up. Still have to modify it for COP.


When you get to the "ill send the CAD files out to mill from billet aluminum" part of this project my brother works for a machining company, programming, running and supervising their mills. They have at least 2 monster 5 axis mills. I don't know if he can save you money but it is worth asking.

Jim
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edwin
post Aug 23 2013, 07:12 AM
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This part has "home cast aluminium" written all over it
You know you want to try it Mark
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rhodyguy
post Aug 23 2013, 07:24 AM
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Chimp Sanctuary NW. Check it out.
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home cast? as in a garage?
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McMark
post Aug 23 2013, 08:01 AM
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Actually I do. Casting has been on my todo list for a long time now. (IMG:style_emoticons/default/boldblue.gif)
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jbyron
post Aug 23 2013, 09:38 AM
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Looking at the pic, I'm concerned whether or not there's clearance to thread a nut onto the stud.
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GeorgeRud
post Aug 23 2013, 06:20 PM
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Yeah, it does look like you might have to lift it, start the nuts, then tighten it down. Then again, they do make shorter studs!!
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McMark
post Aug 23 2013, 06:29 PM
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George is thinking along the same lines as me. (IMG:style_emoticons/default/wink.gif)
The walls on the adapter are pretty thick too, I could probably add some clearance.
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McMark
post Oct 26 2013, 10:59 PM
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Quick update...

Intake manifolds are at the machine shop getting carved from aluminum. (IMG:style_emoticons/default/happy11.gif)
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tscrihfield
post Oct 26 2013, 11:28 PM
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QUOTE(McMark @ Oct 27 2013, 12:59 AM) *

Quick update...

Intake manifolds are at the machine shop getting carved from aluminum. (IMG:style_emoticons/default/happy11.gif)


Awesome! Can't wait to see them!
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veekry9
post Oct 27 2013, 03:49 PM
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This is Great.
Thanks for showing the World the latest in NewFangled Tech.
An Idea to Part in hours and not days,the response time of
CadCam system Integration in Manufacturing Systems.
You too can have your very own Protype shop in your garage.
Just like the Mechanix Illustrated BluePrints of the 60's.
Time to fire up your
[4valve head prototype investment casting pattern]
[transaxle housing]
....anything you can dream up.
the Future is Here Now.
Try the Rhino4 or 5 Cad.
Synergy by Weber is a cost effective Cam.
EMC2 is an OpenSource Machine Control System.
There is a lot of competition in the machining industry for large
systems.50K is likely beyond the pricepoint for the home user.
You have to look around and test,then make the decision that suits you
best for the most you wish to spend.There is a fellow here doing a custom
oil scavenge pan for his V8 conversion,inhouse or subcontracted?
It is possible to do it inexpensively,however,the labour intensity rises
accordingly.
A good example of the technology available today.


https://www.youtube.com/watch?v=r7V57_7H9zw

A 20yr old Hardinge retrofit.


https://www.youtube.com/watch?v=35tHYaDUmZQ

A Large 5axis from the 60's retrofit

If they can do it,so can we.
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