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Author Topic: Sheet Metal Intake Manifold.  (Read 123962 times)

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Offline tauruck

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Re: Sheet Metal Intake Manifold.
« Reply #105 on: January 18, 2016, 09:06:37 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.

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« Reply #106 on: January 20, 2016, 12:58:59 AM »
Pics of the top half under construction.

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« Reply #107 on: January 20, 2016, 01:02:56 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:

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« Reply #108 on: January 20, 2016, 01:06:10 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".

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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.

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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:

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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.

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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. :dhorse:

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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.

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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??????.
Silly me. :dhorse: :dhorse: :dhorse: :dhorse: :dhorse:

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!!!!!!. :-D

Offline Peter Jack

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Re: Sheet Metal Intake Manifold.
« 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.  :-o :-o :-o  :-D :-D :-D

Pete

Offline Dr Goggles

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Re: Sheet Metal Intake Manifold.
« 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??????.
Silly me. :dhorse: :dhorse: :dhorse: :dhorse: :dhorse:

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!!!!!!. :-D

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.....
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.

Offline tauruck

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Re: Sheet Metal Intake Manifold.
« 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!!!!!

Offline robfrey

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Re: Sheet Metal Intake Manifold.
« Reply #118 on: February 16, 2019, 11:15:43 PM »

I built this intake last year. It was my first sheet metal intake. It was not hard to reshape the tubing to fit in the the square intake. I think it was easier than trying to make them square all the way and I think it flows better. On turbo stuff, the simulation says that a little taper on the runners helps power.
Notice that I built up the entrance to the runners with weld then radius them with die grinder. It was a good exercise for my fabrication skills.


Rob Freyvogel
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Offline manta22

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Re: Sheet Metal Intake Manifold.
« Reply #119 on: February 17, 2019, 11:23:14 AM »
Nice job, Rob.

Regards, Neil  Tucson, AZ
Regards, Neil  Tucson, AZ