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Author Topic: Sheet Metal Intake Manifold.  (Read 82464 times)
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tauruck
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« Reply #105 on: January 18, 2016, 10:06:37 PM »

My Carbon plenum is taking shape.
I've got the top and bottom sections bonded.
It needs some shaping and fettling but I'll be able
to start laying up the multiple layers of Carbon and Kevlar
by the weekend. cheers

Pics tomorrow.
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tauruck
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« Reply #106 on: January 20, 2016, 01:58:59 AM »

Pics of the top half under construction.


* PLI1.JPG (70.67 KB, 1024x768 - viewed 210 times.)

* PLI2.JPG (78.05 KB, 1024x768 - viewed 198 times.)
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tauruck
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« Reply #107 on: January 20, 2016, 02:02:56 AM »

After multiple layers it went into the vacuum bag and then you just
wait for the part to cure.

The little spots are the excess resin that gets pulled through the perforated film.
Pull vacuum too early and you'll get a pump full of goo and blocked connectors. evil


* PLI3.JPG (71.3 KB, 1024x768 - viewed 216 times.)

* PLI4.JPG (69.96 KB, 1024x768 - viewed 208 times.)
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tauruck
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« Reply #108 on: January 20, 2016, 02:06:10 AM »

After the part cured I bonded it to the base.

Some beefing up in the critical areas and then I'll be able to
lay up the good stuff. 14 layers I "guesstimate".


* PLI5.JPG (74.04 KB, 1024x768 - viewed 240 times.)

* PLI8.JPG (69.92 KB, 1024x768 - viewed 226 times.)
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tauruck
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« Reply #109 on: April 20, 2017, 11:44:17 PM »

I finally had a few minutes to work on the plenum chamber.
First layer of unidirectional Carbon going on.
Many more to go.


* Plenum 1.JPG (84.42 KB, 1024x576 - viewed 65 times.)

* Plenum 2.JPG (62.97 KB, 1024x576 - viewed 67 times.)
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tauruck
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« Reply #110 on: April 20, 2017, 11:46:03 PM »

Wrapping a component like this is a PITA but I have no other way.
I bagged it an pulled vacuum. We'll know later today how succesful
my methods were. cheers


* Plenum bagged1.JPG (60.37 KB, 1024x576 - viewed 74 times.)
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tauruck
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« Reply #111 on: April 21, 2017, 08:45:19 AM »

I removed the plenum from the vacuum bag
and it looks OK.
The bleeder film is still on the chamber in the photo.
I'm busy post curing the resin and I should have pics of
the part over the weekend.


* Plenum.JPG (78.7 KB, 1024x576 - viewed 75 times.)
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tauruck
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« Reply #112 on: April 24, 2017, 09:22:33 AM »

I was going to hammer some heavy wall Ally tubing from round to rectangular
for each of the 8 runners.
I did one and it was too time consuming and beyond my capabity so I decided
to produce molds and make the runners in Carbon.

The original is very smooth on the ID. I worked it with flapper wheels to a mirror
finish. The OD has hammer marks etc so I'll use some filler and get to work. Dead Horse


* Ru1.JPG (85.35 KB, 1024x576 - viewed 69 times.)

* Ru2.JPG (93.16 KB, 1024x576 - viewed 63 times.)
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tauruck
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« Reply #113 on: April 24, 2017, 09:24:22 AM »

The tooling is complex but it has to be done.
I see a four part mold. 2 inner, 2 outer halves.


* Ru3.JPG (86.09 KB, 1024x576 - viewed 69 times.)

* Ru4.JPG (74.76 KB, 1024x576 - viewed 60 times.)
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tauruck
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« Reply #114 on: April 26, 2017, 12:23:16 AM »

My buddy Ian popped around for a visit yesterday and saw my "wannabee" complex runners.
He asked why I needed to go from round on one end to radiused rectangle on the other?Huh??.
Silly me. Dead Horse Dead Horse Dead Horse Dead Horse Dead Horse

Why?. Why not just go rectangular all the way?. I'll be making changes.
This is what happens when you lock yourself up in the shop and don't see other humans for weeks on end!!!!!!. grin
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Peter Jack
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« Reply #115 on: April 26, 2017, 12:59:52 AM »

We've all been there Mike. Brainstorming with others is a very valuable tool. They don't even have to understand what you're doing. Sometimes a totally different perspective brings out totally different ideas.  shocked shocked shocked  grin grin grin

Pete
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Dr Goggles
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The Jarman-Stewart "Spirit of Sunshine" Bellytank


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« Reply #116 on: April 26, 2017, 06:45:36 AM »

My buddy Ian popped around for a visit yesterday and saw my "wannabee" complex runners.
He asked why I needed to go from round on one end to radiused rectangle on the other?Huh??.
Silly me. Dead Horse Dead Horse Dead Horse Dead Horse Dead Horse

Why?. Why not just go rectangular all the way?. I'll be making changes.
This is what happens when you lock yourself up in the shop and don't see other humans for weeks on end!!!!!!. grin

Staring time. There is no substitute for staring time. And remember, no science is better than bad science....... dometime we so wrapped up that we forget the basics.....
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Few understand what I'm trying to do but they vastly outnumber those who understand why...................

http://thespiritofsunshine.blogspot.com/

Current Australian E/GL record holder at 215.041mph

THE LUCKIEST MAN IN SLOW BUSINESS.
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« Reply #117 on: April 26, 2017, 11:52:33 PM »

Thanks James and Pete. You're both so right!.
My current design looks good but to actually produce the parts
is a PITA.

I can go from the current 63mm ID on the round side to 80.
That will make removing the part from the mold simple.
Attaching the Carbon runners to the manifold creates another
problem so I was thinking of making a wooden buck and shaping
the parts (2) for each runner in Aluminium and get Dunc to weld
them.
Nothing comes easy and I need to take a step back on this. PATIENCE!!!!!
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