Inlet Manifold Design - Triple Injectors
Turbo Mini Forums

Yes, aluminium bar 28mm dia by 250 long to start with.

I was very aware of the possibility of the drill running off centre.

So I made sure that the initial pilot centre was just right, then used good quality sharp drills 4mm, 6.5mm and then 8mm, then did the same at the other end.

Finally, I ran a 250mm long 8mm drill through. There was a little run-out but only a few thou.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

amazing work paul!!

Yes i moved to the darkside

Instagram @jdm_brett

Did you use steadies to support the work or just a chuck, when drilling out?

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Haven't you hot metal glued those bosses together yet!! Come on man we want to see this working!
In fact if you are too scared, send it me and I'll fuck it u...err I mean weld it up......

I am actually planning on Tigging it together myself. But I am f@cking scared

Just need to get some scrap to do some more practising.

Plus waiting for Jason G to update his Tig thread so that I can get some better settings on the welder.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

What about using brass and silver soldering it all together?

What settings do you want? I'd start about 75A I reckon for those, 3.2mm tungsten.

I'd say a bit higher (90ish), and then back off to about 75 once the metal has some heat in it.

but i am a bit all or nothing...

Did you ever get this together?

'91 ERA
http://turboera.com/

We need some more gas to weld it all together, he had a practice to get the courage up!

After a few sleepless nights and a bit of practise on the downpipe, I drummed up the courage to attempt to weld this together.

After a quick test on some scrap pipe to dial in the settings, I leapt in with the torch. It was not easy as the blocks took some heating to get going. Not pretty, but I'm happy with it:


A quick tidy up and we're ready for the nexty step:


Hopefully the rest of it will be easier.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

That looks top notch.

I found the same with dis-similar thicknesses.

After "tidying up" with a die grinder (very coarse burr) I put the TIG over it again to fill in the low bits and it always seemed to look a lot better.....

But then I always wanted it to look a lot better.....


So long as it's leak tight and hasn't distorted the inside of the runners, leave it.

Function over form as they say...

The warmer weather is obviously increasing motivation in a lot of us at present :)

Schrödinger's cat - so which one am I ???

I'm not happy with the inlet to the plenum as per this photo:



Too close or not?

Well the intention is to CFD the plenum and trumpets. With Sturgeo's help we have drawn the plenum and trumpets in 3D in Solidworks and have created an assembly. The next step will be to import the 3D model into a CFD program to analise the flow patterns and maybe the pressure pulses.



Due to our amature status as 3D drafters, we cannot get the trumpets to sit in exactly the right place within the plenum. They just free float.

Anyone give us some guidance as to how to position the trumpets?

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

how about moving the inlet to the plenum away from the trumpet, ie so the hole in the flange is offset.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Sorted

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

Im alright with solidworks, did you draw the 2 parts as separate? it looks like theyre in one part. You could either redraw one part as a new part, then make a new assembly from the 2 parts and mate it together.

Or you could try 3d sketch and do dimensions that way.

In boost we trust

Yes drawn up as 2 separate components and then brought into an assembly.

The next problem is cutting the holes in the sides of the plenum where the trumpets go through. At the moment there is no clear flow path.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

You could modify the plenum in the assembly. And use convert entities to find the arc where the trumpet goes through. Then extrude to next. You might have issues with it saving to the original part though.

In boost we trust

Ive just tried what i said and cant get it to work on a rough model i made. Ill keep trying and ask some mates.

In boost we trust

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."

I got something, but i had put a new plane on a tangent to the plenum in part view and extrude the hole through. Then go to assembly and it will update and youll have to re-mate your trumpets to the holes. But its easy, just use the faces and coincident.
Thats what i got

In boost we trust

Thanks, I'll give it a go.

Saul Bellow - "A great deal of intelligence can be invested in ignorance when the need for illusion is deep."
Stephen Hawking - "The greatest enemy of knowledge is not ignorance, it is the illusion of knowledge."