home made sheet metal intake

[turboglenn]

As long as I have dimensionally correct information of what size the 1g port is, i can give you detailed bend/roll angles for perfect square to round transitions. That's something I have to do quite frequently. Even the fillet isn't difficult to include. The bend lines just have to draw back to a center point longer than the actual piece and it will form a natural fillet.

I've got one in the garage off and just sitting, you want pics of the ports with micrometer showing where i'm measuring and where the radii start on the corners so you can get as close as possible?

I'D BE glad to go snap a few for you, althogh i have issues remembering how to measure radius, have to look it up everytime

 

[H@xtGSX]

Yes! Glenn that would be perfect. For the fillets, all you need to do is draw or infer the horizontal and vertical edges past the fillet, as if the hole were square, to where those straight lines intersect. Measure at 45 to the edge of the fillet from that intersect and record that distance. I can replicate that exactly with autocad. I also need total width of the port, width from the outside edge of #1 to #4, height of the openings, average thickness of the runner walls at the port, and flange thickness.

If you can stick a micrometer on a stock intake, 1g or 2g, and send me info of that level of detail, I can draw it out exactly. Which in turns means a CNC, plasma, or good fabricator can also, quickly and efficiently.

 

[turboglenn]

i'm fresh out the shower headed to bed, i'll post it upin the am for you!

 

[H@xtGSX]

I'm off work today, and am going to be taking my throttle body off to put new shaft seals in, so I will get the dimensions for the throttle flange too while I have an easy opportunity to do so.

Sparky or Glenn, do either of you have a milling machine or CNC you can use to true the flange face? I have access to one, but it'll either cost me $ or a big favor later.

 

[sparky1987]

Me when I get done welding everything I have access to a surfacer to make everything flat if that helps.

 

[2gmummy]

I was thinking if you angled the inlet by the throttle body a bit more towards the front of the car to reduce the angle of the ic to tb might help and then in the area before the split into two make like a bubble to collect some air and then you can plug all your lines in there. Also where are you planning to mount the bracket to keep the throttle cable still?

 

[H@xtGSX]

I was thinking if you angled the inlet by the throttle body a bit more towards the front of the car to reduce the angle of the ic to tb might help and then in the area before the split into two make like a bubble to collect some air and then you can plug all your lines in there. Also where are you planning to mount the bracket to keep the throttle cable still?

Good thinking. That's pretty close to exactly what I thought also. I was going to use a short piece of 4" pipe with 2 concentric reducers to make a bulge just prior to that top elbow where the vacuum lines could be tied in. The throttle it self would be relocated upstream on the IC pipe, closer to the fuse box (positioned so both SMIC and FMIC piping could be plumbed to it without major problems), with a set of brackets with slotted holes welded to the pipe itself. The throttle cable would have to be either cut shorter (not what I'd do, but would look cleaner), or just pulled in a slightly tighter loop to the bracket. This way there's a similar air reserve inline with the piping and the throttle position issue is somewhat addressed. There's going to be more problems, for sure, and I still have yet to get the 3D model flow tested in a fluid dynamics simulator. If that shows an improvement over the traditional SMIM, I'll go into the details further. I don't want to commit to a single design unless there's a good reason to continue spending time on it. I have also been thinking about doing a 1 into 4 design that is a wrap over design, much like an equal length tubular exhaust header.

 

[turboglenn]

damn, i spaced it off you still need those head measurements? PM me if so that way i can't forget and ill measure and get pics even ASAP

Sorryfor thedelay., had some bills pop up and hgave been rushing to get enough work in to cover everythign

 

[H@xtGSX]

No problem Glenn. I am bogged down doing concrete drawings for a huge 5 stage air compressor set up... Each compressor need a concrete footing, piping, and 440 electrical lines trenched in off a run of 12470... I have fiddled with it a little, but nothing major since we last talked. I do still need those 1g dimensions. Port size, spacing, wall thickness between ports, and basic flange/gasket dimensions for the triangles in relation to the ports. Don't make it a chore Glenn. I can manage either way... But I only know one other guy with a 1g and I hate interrupting his build for me to poke around on his motor. So, what you're doing is a favor to multiple people.

In addition, once I have a cnc confirmed flange match, I'll publish the dimensions on here so it is no mystery for us private fabricators willing to do this sort of work.

 

[2gmummy]

If it works for 1gs you'll mak 2g ones riiiight??

 

[DSM_love_GST]

willing to test this one as well

 

[turboglenn]

haha i have a feeling when one gets built people to test will not be in short supply

 

[sparky1987]

Yeah for sure im sure it wouldn't be too hard to adapt this for both models. And glenn you know it people will be coming out of the wood work to test something new and innovative.

 

[DSM_love_GST]

Well I am already testing one of sparky's that can be picked up for $300! Quality work I must say!

 

[H@xtGSX]

I drive a 2g, so yes, a version for both.

 

[Diamond Star Werks]

Nice work bro, clean welds too. Good job Make one for my car

 

[simple jake]

I'd say I would test it out but I don't make enough power to make any difference . But if you do end up selling the completed version for 300 then I will definitely be buying one off of you!

 

[DSM_love_GST]

updates?

 

[H@xtGSX]

My update: Stagnation. I am having trouble finding an adequate fluid dynamic software I can beg, borrow, or steal, and I have been having a real bad case of drafter's block right now. I dont want to do schitt with AutoCAD right now, I am sick of looking at it. I have been working one boring project on top of another for a week straight and I am starting to have AutoCAD dreams.... And that's a bad sign. It's getting painful to just look at it now, and today I spent more time farting around on here than working... Ugh. Sometimes I love what I do, and sometimes it makes me want to stab myself in the eye with a handful of fish hooks.

 

[ed1380]

solidworks? They have flow simulation

 

[H@xtGSX]

solidworks? They have flow simulation

I know. That's what I have been looking for, since I can directly import 3d objects from ACAD. No one I know has a copy, and I haven't been able to find a clean... Uh.............. "other" copy. So I've been looking for anything with a thermodynamics or fluid dynamic simulation that could take the raw 3d data and test it.

 

[tkelly27]

Solidworks is kind of a toy when it comes to FEA and CFD.

The OpenFOAM&#174 Foundation

Wish I could tell you I knew how to use that. The other programs are big $ per seat and you'll probably have to hang out in a back alley at an engineering school to get a copy.

 

[H@xtGSX]

Solidworks is kind of a toy when it comes to FEA and CFD.

The OpenFOAM® Foundation

Wish I could tell you I knew how to use that. The other programs are big $ per seat and you'll probably have to hang out in a back alley at an engineering school to get a copy.

I saw that openfoam program while looking for a way to flow test some chute work I was doing a while back... Universities are good sources for open source engineering programs. I tried figuring out how that was supposed to work, but all I saw was a bunch of code gibberish I have no idea what to do with. There's a rumor I have heard a couple times now that someone made a piggyback program for AutoCAD that does FEA, though the particle count has to be kept within the available computer capacity, and that normally isn't massive when talking about millions of particle physics calculations per second. I have still yet to see anything like that though. It sure would be nice, as I am an AutoCAD ninja.

I'm going to start a "please use your FEA software on my design for free... Please please please" thread.

 

[Arthris]

Its for linux. Make a duel boot setup and run it. I thought I hade a copy of solidworks but idk if i do. Thought i was given a copy of the 2008 or 2007 edition back in HS. ill look around my boxes

 

[simple jake]

Find a program to test it out yet? I've got access to Solidworks in my AutoCAD class but I don't know how to use the fluid dynamics on it