CNC Billet Injector Bosses and Manifold
Turbo Mini Forums

I did consider casting but all the messing about with the sand moulds for each one put me off. Plus it would still need a lot of machining.

Although it takes time, we now have confidence in the G-code such that we can set a 2 hour operation on the go and just leave it whilst we get on with something else.

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."

:cool:

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."

They look great! Hats of to you sir.

My build thread: http://www.turbominis.co.uk/forums/index.php?p=vt&tid=454802

Flickr: http://www.flickr.com/photos/85313398@N02/

That's a nice bit of whittling.

Prize?, for a par..looks nice

Less then 8", is too small...

brill.

Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM

Very nice :)

WOW! Cant wait to see those in action!

look great. any thoughts on cost yet? we talking £40 or £140? (or something else)

1275 N/A Sprite, 998 T2 Turbo Mayfair
1275 EFi Turbo

Well, those two took four days to make and about £1200 investment in kit.

Taking labour, material, consumables and electricity costs into account, I don't think that I can offer them at a price that will sell :( A price of £140 each would be giving away my spare time.

Hats off to the guys like DSN who can turn out thermostat housing at just £45 each. They must make 100s at a time and have several machines going at once to cut down the labour cost.

I'm going to make 4 more for our own projects for now.

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 think someone going down this route for fueling will be putting a fair amout more money into other stuff, decent injectors are not cheap, the ecu are getting simpler but still not cheap all the leg work and testing ontop, the engine will likely be an expensive affair and the builder wanting the 'best' way to fuel the five port a couple hundred quid per port starts looking more like a realistic price,
ahh and by the way they look great

Yes i moved to the darkside

Instagram @jdm_brett

Paul- I make bits and pieces on my mill too, and struggle to believe how cheap DSN sell their stuff, especially being annodised too!

www.topcatcustom.co.uk

Whats DSN's material like though?

not trying to knock them, but for somthing like a stat housing you could use any crap grade ally, that can make a big difference to cost.

DSN stuff is good quality, not sure of the grades of aluminium though.

Material cost is not a major issue. The bosses are cut from 2" of a 3" square bar which costs about £8 a time.

The problem is that you end up with £2 worth of material and the cost is in what you don't use..... if you see what I mean :)

I've just placed a big order with DSN for stuff that I thought I might make myself, but now realise that I just wont have the time.

Edited by Paul S on 14th Nov, 2012.

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."

DSN are using purpose made-machines with tool changers, running inserted tools that can plunge and cut probably 40 or 50 times faster. You'll never compete with that. They also buy 6061 at rates everyone else can only dream of - and make enough chips to get a good return on these at the recycler too.

I just wonder - I haven't looked into this - but are there companies out there somewhere that just take the code and churn out the parts cheaply because they have the bigger equipment ???

I haven't made a PCB myself for at least four years since Jean suggested to me a company in HK/China and I now just spend my time on design and email them the gerber files and two weeks later I have the boards.

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

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."

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."

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

Fuel rails are nice and easy :)

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 know it was soemthing called emachineshop.com where you could draw your parts and get a pricequote for the job. I have not tryed it myself, and the website is down at the moment I think

www.shag.no

Last time I looked at emachineshop it could not handle the angles.

Anyway, we've got the material to make 4 more bosses ourselves.

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."

Very impressive Paul!

Question on the fuel rail; where did you get it?
I have been looking for a small piece for my set-up.

Dazed and Confused....

Fuel rail blank comes from Ross Machine Racing in the US:

http://www.rossmachineracing.com/dash6.html

Adapters are from ebay - hope they seal OK

http://www.ebay.co.uk/itm/6-AN6-06-to-9-16...=item27c712e1f8

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."

Trigger wheels now sell the fuel rail