Building a custom inlet manifold for YB
08-04-2014, 08:11 AM
#83
Too many posts.. I need a life!!
Thread Starter
Thanks guys. I've got all the materials, machining and casting for free so the total cost for me personally is the cost of the parts bought from Jenvey; which I also got at a great price! Total spent is about £500.
If you count hours spent its about the same amount, maybe as much as 800!
If you count hours spent its about the same amount, maybe as much as 800!
Last edited by nixon_2wd; 08-04-2014 at 08:24 AM.
07-05-2014, 06:49 PM
#85
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Thread Starter
Some more progress on this. Just got the lower plenum molds ready, so now it's time to make sand molds on it and cast the final piece, then off to the rest of the machining! This project is finished soon 
Hoping to cast it and do the final machining next week!
Hoping to cast it and do the final machining next week!
Last edited by nixon_2wd; 07-05-2014 at 06:58 PM.
15-05-2014, 04:18 PM
#87
Too many posts.. I need a life!!
Thread Starter
Back in the workshop and some progress!
Machining to accept lower plenum:
Then casting the lower plenum!
The casting got a little fucked due to the two half molds not aligning correctly (about 3mm shifted at the back end), but the overall shape and surface quality was great, so of course I had to trim the gating system off and test fit it
Also did a fuelrail:
As the first casting got fucked I had to spend another 8 hours at the foundary building molds, readying the machines etc, however, the second one turned out great!
Will be back tomorrow hopefully with the whole thing finally assembled!
Machining to accept lower plenum:
Then casting the lower plenum!
The casting got a little fucked due to the two half molds not aligning correctly (about 3mm shifted at the back end), but the overall shape and surface quality was great, so of course I had to trim the gating system off and test fit it
Also did a fuelrail:
As the first casting got fucked I had to spend another 8 hours at the foundary building molds, readying the machines etc, however, the second one turned out great!
Will be back tomorrow hopefully with the whole thing finally assembled!
15-05-2014, 07:08 PM
#88
Wahay!! I've lost my Virginity!!
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once again first class work, its people like yourself making parts like this that got ybs a lot more horse power all them years ago, a1 work and skill, a real credit to you, as before I know how much time is spent just setting up the machines
, so you have my full respect for this epic project, keep up the good work.
, so you have my full respect for this epic project, keep up the good work.
19-05-2014, 07:41 PM
#89
Too many posts.. I need a life!!
Thread Starter
Thanks mate!
Got the thing assembled with the lower plenum
Sorry for the blurry pictures, the camera lens is totally scratched up.
Also wondering what injectors to use for 550bhp? Should I use different spray pattern ones on the rear compared to the fronts? Will be 8 fully sequential driven injectors.
Got the thing assembled with the lower plenum
Sorry for the blurry pictures, the camera lens is totally scratched up.
Also wondering what injectors to use for 550bhp? Should I use different spray pattern ones on the rear compared to the fronts? Will be 8 fully sequential driven injectors.
Last edited by nixon_2wd; 19-05-2014 at 07:45 PM.
22-05-2014, 03:38 PM
#90
Advanced PassionFord User
What ECU? The ones on the plenum should be a straight shot pattern as opposed to a cone spray like the ones in the actual manifold. You'll ideally need an ECU which can alter the injector timing too
22-05-2014, 04:04 PM
#92
Advanced PassionFord User
31-05-2014, 02:23 PM
#93
Too many posts.. I need a life!!
Thread Starter
Been at it again today, trial fitting some of my new parts. The new spec will be finished hopefully by october / november. There's a new tubular manifold from MAD paired with a EFR7670 1,05. In a week or so my new 63mm Pro Alloy 3" intercooler will be fitted.
Going to rebuild the whole engine with 136mm rods, new pistons, ported head with double valve springs etc.
Got a plenum spacer for my inlet, makes it look awesome.
Andreas
Going to rebuild the whole engine with 136mm rods, new pistons, ported head with double valve springs etc.
Got a plenum spacer for my inlet, makes it look awesome.
Andreas
Last edited by nixon_2wd; 31-05-2014 at 02:55 PM.
16-10-2017, 11:06 AM
#96
Too many posts.. I need a life!!
Thread Starter
Got a small step further on this project. Had to weld on some tabs for the return springs, idle screw and TPS bracket. Got it all sanded and powdercoated. Bearings now pressed in, seals fitted, throttle linkage hooked up and sorted.
Currently waiting for my injector sockets to get finished as I dont have direct access to a workshop at the moment. A friend is making those.
Next is to make some fuel rail brackets. Got a new set of fuel rails as I didn't like the weight of the old raw stock I got.
Also, just got my Supra diff built up with the Weir kit, and fitted to the car.
Block is currently being fitted with cylinder liners, 10 longstuds and zetec oil jets.
Got my cylinder head back so it's now ported, new valves fitted, valve spring seats are machined lower in the head to accomodate for higher lift and double valve springs.
Andreas
Currently waiting for my injector sockets to get finished as I dont have direct access to a workshop at the moment. A friend is making those.
Next is to make some fuel rail brackets. Got a new set of fuel rails as I didn't like the weight of the old raw stock I got.
Also, just got my Supra diff built up with the Weir kit, and fitted to the car.
Block is currently being fitted with cylinder liners, 10 longstuds and zetec oil jets.
Got my cylinder head back so it's now ported, new valves fitted, valve spring seats are machined lower in the head to accomodate for higher lift and double valve springs.
Andreas
16-10-2017, 11:49 AM
#98
10K+ Poster!!
Wow, that all looks great
16-10-2017, 03:34 PM
#99
PassionFord Post Troll
Work of art mate id be very proud of that
17-10-2017, 07:29 AM
#101
Too many posts.. I need a life!!
Thread Starter
Hehe, my MSc was finished 3 years ago. This was not my thesis, I just decided to build it as I had the chance. Been saving up for an appartment since then. I am building a new workshop at the same time to build the car, and just recently got back on track on the car build.
Currently saving up for a Haas VF2 for maybe late 2018 so I can start production of the manifolds etc.
Last edited by nixon_2wd; 17-10-2017 at 07:31 AM.
17-10-2017, 07:34 AM
#102
I would have to go back to check the results as I can't remember right now. The runners are 180mm long compared to 108mm on the standard manifold. Thats a 67% increase which makes a huge difference on the torque curve.
Hehe, my MSc was finished 3 years ago. This was not my thesis, I just decided to build it as I had the chance. Been saving up for an appartment since then. I am building a new workshop at the same time to build the car, and just recently got back on track on the car build.
Currently saving up for a Haas VF2 for maybe late 2018 so I can start production of the manifolds etc.
Hehe, my MSc was finished 3 years ago. This was not my thesis, I just decided to build it as I had the chance. Been saving up for an appartment since then. I am building a new workshop at the same time to build the car, and just recently got back on track on the car build.
Currently saving up for a Haas VF2 for maybe late 2018 so I can start production of the manifolds etc.
Nice machines the Haas range. Thats some saving up pal.😉
17-10-2017, 07:58 AM
#103
Too many posts.. I need a life!!
Thread Starter
How did you get to work with GT? We got it through the university formula student team. I was responsible for the engine tuning and did a lot of studies on the effects of intake / exhaust runner lengths, diameters, exhaust runner stepping, and variable intake runner length, cam timing and dynamic CR. I designed the intake and exhaust manifolds in NX, and cam profiles in vtdesign.
We built and raced a dual runner length intake manifold for the 2012 car placing 16th out of 132 - our first year of competition
We built and raced a dual runner length intake manifold for the 2012 car placing 16th out of 132 - our first year of competition
Last edited by nixon_2wd; 17-10-2017 at 07:59 AM.
17-10-2017, 08:21 AM
#104
Too many posts.. I need a life!!
Thread Starter
My uni is on its 5th year competing in formula student. Since 2015 they've had 3d printed uprights on the cars, but 2017 was the most extreme. Thought I'd show this although I've not been involved in any of the design / analysis of this thing. It's topology optomized, meaning that the part is designed and subjected to load cases, then through topology analysis software all elements below specified strain energy limit are removed, and you are left with this sort of organic shape.
The part is then thoroughly analyzed to verify the design before it is 3d-printed in titanium.
The part is not solid, its hollow with internal support structure, making it extremely light, reducing unsprung mass.
The part is then thoroughly analyzed to verify the design before it is 3d-printed in titanium.
The part is not solid, its hollow with internal support structure, making it extremely light, reducing unsprung mass.
Last edited by nixon_2wd; 17-10-2017 at 08:22 AM.
17-10-2017, 10:20 AM
#105
I've found that life I needed.. It's HERE!!
I had to machine a 3D printed titanium plane engine casing the others day
It weren't nice to machine but now it's gone to have all the flanges and bits printed
On it
Clever stuff
We do loads of stuff like that at work
We also spray titanium on things then release it leaving a awesome
Titanium component
It weren't nice to machine but now it's gone to have all the flanges and bits printed
On it
Clever stuff
We do loads of stuff like that at work
We also spray titanium on things then release it leaving a awesome
Titanium component
17-10-2017, 09:35 PM
#106
How did you get to work with GT? We got it through the university formula student team. I was responsible for the engine tuning and did a lot of studies on the effects of intake / exhaust runner lengths, diameters, exhaust runner stepping, and variable intake runner length, cam timing and dynamic CR. I designed the intake and exhaust manifolds in NX, and cam profiles in vtdesign.
We built and raced a dual runner length intake manifold for the 2012 car placing 16th out of 132 - our first year of competition
We built and raced a dual runner length intake manifold for the 2012 car placing 16th out of 132 - our first year of competition
So many variations, so many DOEs that have run for days.
Lots of surprises and unrealistic results in some cases. I still use it now.
Have access to cnc 3 axis at work and 3d prototyping, not metal layup though.
Was looking at Formlabs gel printing last week
Ace stuff.
18-10-2017, 07:21 AM
#107
Too many posts.. I need a life!!
Thread Starter
First got it on my degree programme. Have followed it through since i finished. Modelled my restricted rally car engine looking for improvements.
So many variations, so many DOEs that have run for days.
Lots of surprises and unrealistic results in some cases. I still use it now.
Have access to cnc 3 axis at work and 3d prototyping, not metal layup though.
Was looking at Formlabs gel printing last week
Ace stuff.
So many variations, so many DOEs that have run for days.
Lots of surprises and unrealistic results in some cases. I still use it now.
Have access to cnc 3 axis at work and 3d prototyping, not metal layup though.
Was looking at Formlabs gel printing last week
Ace stuff.
21-10-2017, 06:48 PM
#109
I would have to go back to check the results as I can't remember right now. The runners are 180mm long compared to 108mm on the standard manifold. Thats a 67% increase which makes a huge difference on the torque curve.
Hehe, my MSc was finished 3 years ago. This was not my thesis, I just decided to build it as I had the chance. Been saving up for an appartment since then. I am building a new workshop at the same time to build the car, and just recently got back on track on the car build.
Currently saving up for a Haas VF2 for maybe late 2018 so I can start production of the manifolds etc.
Hehe, my MSc was finished 3 years ago. This was not my thesis, I just decided to build it as I had the chance. Been saving up for an appartment since then. I am building a new workshop at the same time to build the car, and just recently got back on track on the car build.
Currently saving up for a Haas VF2 for maybe late 2018 so I can start production of the manifolds etc.
22-10-2017, 06:15 PM
#110
Too many posts.. I need a life!!
Thread Starter
Yes mate. PM me.
You´re spot on. The runners on Cosworths are very short as standard.
Thanks mate.
Thanks mate.
12-12-2018, 09:03 AM
#111
Too many posts.. I need a life!!
Thread Starter
Piece of **** Photobucket has destroyed this thread, so I will include a pic of the inlet in the engine bay:
Its been a while but I have finally got my VF2. Hopefully going to start production soon
Currently waiting for the installation guys to set it up.
Its been a while but I have finally got my VF2. Hopefully going to start production soon
Currently waiting for the installation guys to set it up.
12-12-2018, 10:32 AM
#112
PassionFord Post Troll
Wow some set up production of?
12-12-2018, 11:14 AM
#113
10K+ Poster!!
WOW, how much do you think they will be?
18-12-2018, 11:33 AM
#117
Too many posts.. I need a life!!
Thread Starter
18-12-2018, 07:57 PM
#119
10K+ Poster!!
Just searching for a pic of my myford 7 to blow you guys away...lol