Twin Seq. Dry sumping for beginners :D

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gareth
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Sun Oct 20, 2013 7:55 pm

That's a tidy looking bit of steel you have there :) Will the 'drain ports' (sticky outy bits!) be lower than the x-member? Just thinking if they are that it wouldn't hurt to add a ramped but of steel to the leading edge to stop it digging into anything it touches, a bit like BMW did with those natty little fins that stick down on the rear of the front wishbones, protecting the lollypops :)

They just look a bit sharp to me and i can see them taking a bit bite out of one of those nasty little rubber speed bumps whereas bumping up and over would be unpleasant but less rearward force.

You've probably got that all covered but i though it would be worth mentioning if not! Top work my man! :D
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Mon Oct 21, 2013 2:56 pm

Cheers dude, hadn't given too much thought to it hitting things, other than wanting to make it of steel for strength reasons :D

The lowest part of the sump will be higher than the cross member I think, the deepest part is about 2"

There is a bit of a ramp to the front at the moment, but it does have a sharp downward projection.

Luckily enough, the chap who did the laser cutting, cut up the left over steel (all 20kg of it!) into 300x300 squares so that I could make other things like ramps and guards from it :D
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Mon Oct 28, 2013 2:04 pm

Bit more welding done this weekend, The sump has taken on a bit of a bow so the conrod bolts juuuuust clip it now. Nothing a nice thick gasket won't sort :)


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Need to make some spacers and other ali parts so that I can finish the front of the sump off.

Got prices for the ali parts, but with a baby due in the next couple of weeks, I'm gonna have to cast them instead! :)
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Sun Nov 03, 2013 7:19 pm

Got the pattern for the front spacer done this weekend, just a couple more to do before it's time to break out the furnace :D

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gareth
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Sun Nov 03, 2013 11:31 pm

Now this i like the sound of! :D
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Fri Mar 14, 2014 10:58 pm

Some progress!
Much internets research and experimenting with the arduino has almost yielded a control system that should do the job.
Wasn't quite as difficult as I'd feared, just lots to absorb! :-)
Also got the front seal housing machined one lunch time this week, and ordered the spacer for it, having decided I don't have time to make it myself :-)
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Sat Mar 15, 2014 7:12 pm

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Sat Mar 15, 2014 10:35 pm

Lego the building blocks of awesomeness! Fact! :D
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Tue Aug 11, 2015 1:18 pm

Has any more happened with this project?
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Fri Sep 11, 2015 10:21 pm

Spent about 6 months getting ready to move house.....and then moved house!

The only progress I've been able to make over the last 18 months or so has been learning how to program microcontrollers and getting stuck into the software which will control the turbos.

Edging closer, and a couple of guys at work are on my case daily to make some progress!
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MarkT
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Mon Oct 19, 2015 11:21 am

Glad to hear it. Did the new house include a good workshop?
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Wed Nov 11, 2015 3:08 pm

Jesus, I thought this one was dead. Good to see it's still going.
2.8 development thread http://www.e30zone.net/modules.php?name ... c&t=170822

m3.3.1 m20 thread - now running, chip needed - any volunteers?
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Mon Dec 28, 2015 9:24 pm

No workshop unfortunately, just a tiny garage.....so need to extend that!

Built myself a barn at the last house, hadn't realised just how big it was until I tried to squeeze everything into the new garage!

Have finished the mapping software!

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Not much to look at, and doesn't cater for traction control yet, but now I know what I'm doing that should be easy.

Wanted to be able to map boost levels on the fly, so with this software, all you do is click on the relevant graph and it instantly maps the value to the ECU.

In the background, boost is also mapped against throttle position.

This may not work at all as an approach (target boost against throttle position) but only one way to find out.

Next step is to make up the actuators and mock up the system.
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Sun Mar 04, 2018 8:57 pm

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Steve
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Mon Mar 05, 2018 7:40 am

Wow is this build still going !
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Mon Mar 05, 2018 8:47 am

Year 11!
Marriage, three house moves, a tonne of diy and kids have slowed progress a bit.
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Steve
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Mon Mar 05, 2018 8:52 am

I hear you ! I started my project the same time I started a family, the two don't work well together :D
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Tue Apr 03, 2018 7:49 am

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Second attempt to melt aluminium using the power of electricity. First attempt one of the 25A SSRs blew up......with only 8A going through it.
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Sat Apr 06, 2019 7:43 pm

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Built myself a CNC milling machine.
Hooray!
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Mon Apr 08, 2019 11:28 pm

Designed an actuator for the wastegates, air valve and traction control.

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Mon Apr 22, 2019 5:55 pm

Pattern block for manifold version.....errr 10?

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Wed Apr 24, 2019 4:59 pm

Half a pattern, half machined.

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Steve
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Thu Apr 25, 2019 12:56 pm

10/10 for effort and keeping this project going, when do you think it will be finished?
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Sat Apr 27, 2019 10:33 pm

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Sat Apr 27, 2019 10:34 pm

Ooh, give it another ten years!
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Tue May 07, 2019 6:59 am

Just needs smoothing and a lick of paint:)

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Sat May 11, 2019 9:58 pm

Core box half


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Sat May 18, 2019 3:33 pm

The power of CNC is amazing, can't even see the split line in the finished core

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Sat May 18, 2019 6:16 pm

those cores look like pretty good quality (i used to work in a core shop in a foundry),

looking forward to some more updates.
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Sun Jun 30, 2019 10:15 am

Found a fatal design flaw with the curved manifold; didn't leave enough room to get an air box on! :roll:

Gone back to a design I've made a few times over the years.

Took me a loooong time to figure out how to break the pattern down to be casting friendly!

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Finished the core boxes last night, need to fix the furnace next and see where we end up :D
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Wed Jul 03, 2019 9:00 pm

Core boxes done and tested :-)

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And furnace fixed...hopefully!

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Steve
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Fri Jul 05, 2019 10:49 am

Witchcraft ! I can't even pretend understand half of what you do but I love every update. :thumb:
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Fri Jul 05, 2019 12:38 pm

Steve wrote:
Fri Jul 05, 2019 10:49 am
Witchcraft ! I can't even pretend understand half of what you do but I love every update. :thumb:
i can understand the part about mould/core making as i used to work in the core shop in a foundry a while back.

the rest is all black magic to me.
if it's got t*ts or wheels it's bound to be trouble...............prove me wrong.
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martauto
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Sat Jul 06, 2019 12:48 pm

steve_k wrote:
Fri Jul 05, 2019 12:38 pm
Steve wrote:
Fri Jul 05, 2019 10:49 am
Witchcraft ! I can't even pretend understand half of what you do but I love every update. :thumb:
i can understand the part about mould/core making as i used to work in the core shop in a foundry a while back.

the rest is all black magic to me.
Proper engineering lads !!!
Well done that man :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap: :clap:

Mart.
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Sat Jul 06, 2019 11:23 pm

Furnace worked almost flawlessly tonight. Did trip the RCBO once, but was fine after that. Poured when the furnace reached 730C.

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Couple of defects :-(

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The bottom of one runner didn't fill, and there's a funny step in a thicker part of the casting which shouldn't be there!

Somehow, managed to cast some 1/4" rods!

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These are the core vents!
Amazed that metal would go all the way into a the core prints and back down the vent but not fill all of the casting!

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Good news is that the shrinkage allowance seems to be just about right.

The casting is way too heavy so need to machine the pattern down and thin out the flanges! Almost ran out of metal from the crucible!
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