Twin Seq. Dry sumping for beginners :D

[Turbo-Brown]

Woo hoo! Started welding things into the sump last night!

Started off by finding out exactly how high the pump needs to be using these conveniently sized brass bars. There are some little spacers under the bars just to bring them up a bit.






Next up is to take everything apart and jig it up for welding. Even more convenient than the brass bars was the fact that the mounting plate needed to be exactly 3" from the side of the sump, hence the big block of ali over in the back there.




Last job of the evening was to start making little arms to weld in place:






Where space allows, there will be full width bridging pieces spanning the sump.

The basic idea was to find the height of the pump, replicate that on the jig, then secure the mounting plate to the underside of the jig and weld it in place. Once it's all in, I'll skim the plate flat and any final adjustment of the pump will be done using shims.

Hopefully, more to follow from tonight!

[Turbo-Brown]

Gleee! We have minimal warpage!

Have finished off the lateral braces for the plate this evening:




And also knocked up a more substantial vertical brace. This runs over a main bearing cap so there's nothing moving too near to it






Next up is making the crank scraper and welding this in place. There are two clashes to resolve too where number 1 and 2 conrods hit the plate. No1 can be resolved by a simple pocket in the plate, No2 needs the middle of the plate to be removed so will have to reinforce it again.

Once all the welding's done, the plate will be skimmed flat and drilled and tapped to accept the pump

[DanThe]

Nice nice, re the casting job, wouldnt you be better off with a small gas bottle? Loads about and they are made from steel rather than ally

[Turbo-Brown]

Well, still going! Moving house again soon, so that's taken priority, and once we're all moved in (assuming everything goes to plan with the move) there'll be DIY galore!

In the mean time, have been fiddling around with castings for the inlet system.

Wanted to reduce the size of the throttles (48mm is way too big for the M20 unless you're making serious N/A power!)

This was just a proof of pattern casting so it's rough, but things never work out how you expect (when you're a rank amateur like me anyway!)

So you start out with a pattern:




Mold it up:






You need something to make the hole through the middle:




And that's it!




There's a great big hole over the other side, the core needs modifying to give equal wall thicknesses all round

Next up, making the throttles and oil breather!

[MotorKnyttet]

Aaaaa! There You Are! Now me are very happy.



// Tobbe

[DanThe]

What, no pictures of fire and molten metals?

[Turbo-Brown]

Can ya tell what it is yet?



Still no house unfortunately!

Merry Christmas everybody!

[DanThe]

Looks like a bit of old tree from here

[Dezzy]

Wood turning is for the close to death!

[Coyote_ar]

nice throttle body core

[MarkT]

Update?

[Turbo-Brown]

It's been a very long time since I last got the chance to work on the car, DIY, marriage and changing jobs have all taken priority for a good couple of years.

However, two weeks ago, I threw my back with the consequence that I can't do anything other than sit.

"Not especially conducive to working on a car!" I hear you cry, but having some enforced thinking time has probably brought the project a couple of steps forward.

This is the third revision of my dry sump system.

A while back, the idea was to mount the pump in the sump, chain driven by the crank.

However, revisions 1 and 2 of my design ended up with the sump being no higher off the ground than standard so I had a bit of a re-think.

Then it occurred to me that the jackshaft could be pressganged into driving the pump, still using a chain.

This means that the sump pan itself can be extremely shallow, the pump is out of the way of rock, speed-bumps and road kill and still has a proper, robust drive system.

Will be making sure that the pump will clear the block properly and then sending drawings out this week, the idea being to have the tinware made by others, then weld it together myself. Machining will also pretty much have to be subbed now as I don't have the facilities I used to

Wish me luck!

[maggspower]

Jesus, Mary and Joseph, a blast from the past

Sorry to hear you have done your back in, but glad its put the car back on the agenda

[Turbo-Brown]

Well, made some revisions to the oil pick-up areas so that they fill with oil quicker, and did some full size mock-ups to check everything will fit.

Drawings produced and have just sent them to all my favorite machine shops (all 9 of them!)

Believe it or not, there's 18 machined parts and 12 sheet metal parts to be made in there!

It's taken pretty much a full 40 hours to design and document all of that, although for once (for once on one of my own projects that is!) there's proper documentation and I've resisted the temptation to go "I'll sort that out as I go along". Benefits of the bad back I guess!

Wonder what the prices will come back like!

[Turbo-Brown]

Yikes, looking at around £1k for all 30 parts!

[gareth]

Ouch!
Should have kept all of your small change the whole time you've been planning this, then the piggy bank could pay happily!
Top marks for persisting with it though

[Rav335uk]

Welcome back..

[gareth]

Not been gone Rav, just not been on here all day every day. Life gets in the way sometimes....!

[Turbo-Brown]

Funnily enough, I've an account which I pay £50 a month into. (set this account up, while drunk, as a student!)

Historically the amount in this account has, extremely conveniently, been enough to cover some expenditure on the car or whatever else has taken my fancy at the time.

Guess how much is in the account at the moment

[Jimbob]

£1,000?

[Turbo-Brown]

Bingo!

Just waiting to hear back on where I can save some costs (splitting orders and the like)

Looking hopeful for orders going out this week with sheets turning up in 7-10 working days!

[rix313]

I was thinking about this thread the other day and was wondering what happened, good to see you're back

[Morat]

It's like 2011 all over again!!!
Welcome back, I'm looking forward to more updates

[Turbo-Brown]

Woo hoo!

£430 spent so far, about £600 to go

[Turbo-Brown]

Picking up the first machined parts week after next!

[goosiegander]

Picking up the first machined parts week after next!

YAY! Updates

[appletree]

Happy days!

[Turbo-Brown]

Yay! Been sent a piccy from a very kind forum member who's doing some of the sheet steel for me

[appletree]

Any pics of the car this engine will eventually end up in? And the condition of it at the minute or are you going to be searching for another shell/car?

[Turbo-Brown]

Here's the only pic I can find!

It's in a garage now though, and the quite pink paint you see here is now very faded!



Still plan to paint the fixed panels matt black and re-manufacture everything that unbolts in CF though

The shell itself is pretty sound, had new sills before I bought it, but the guy who replaced them said the rust was only cosmetic.....apparently!

[Turbo-Brown]

Woo!

Shiny bits!

Beautifully made by the good folk of March Precision Engineering, Aldershot

[goosiegander]

Nice!

Crack on mister!

[goosiegander]

You're not too far away from Kos, just get him to deoxidise the paint, you'll be surprised how well it'll polish up!

[gareth]

shiny bit porn!

[Turbo-Brown]

Woo! Have done some welding on the new sump

An extremely kind forum member profiled and folded these parts for me and they all fit together beautifully!

Got the crank scraper welded in, lots of clamping and very low current kept this flat




Uncovered a bit of a design flaw in that something got in the way of the crank turning, not an important part so it could be cut out!