Twin Seq. Dry sumping for beginners :D

[Turbo-Brown]

Three hours to set up and drill two holes that meet in the middle.

Never believed I'd manage to get them to line through!

[martauto]

Nice piece of work mate
Alot of thought and good prep does pay off.

Mart.

[Turbo-Brown]

Had to hone the last two into alignment. Just a fraction out.

Butterflies tomorrow!

[Turbo-Brown]

Took a lot of chopping and filing the throttle to get the thermostat to fit

[steve_k]

loving the work so far.

you thinking of selling any afterwards?

[Turbo-Brown]

Cheers dude!
If there was enough interest in a group buy I could be tempted.
Would sub out most of the manufacturing though, you can see how long it's taking me to make just one set!

[steve_k]

Cheers dude!
If there was enough interest in a group buy I could be tempted.
Would sub out most of the manufacturing though, you can see how long it's taking me to make just one set!

i'm sure there would be interest,
as for subbing the work, i can see your point.

[Turbo-Brown]

Spindle 1 of 3 in progress....after taking forever to make a fixture

[Turbo-Brown]

Two spindles done today

[martauto]

Just loving this

I wonder how many people actually realise how much thought ,time, and above all ...the skill level it takes to even think about doing this ??

Mart.

[Turbo-Brown]

Last spindle finished (managed to put one of the holes 1mm away from where it should be! )

Made the butterfly blanks too.
Tool on the left goes in the lathe so the butterfly diameter can be turned.

[Turbo-Brown]

Oops, One bore is not only 0.4mm oversized, but has a random hump right where the butterfly should sit. Will have to re-bore that one to 40.5mm and make the butterfly to suit

Other than that, productive arvo! Used the mill as a lathe. Amazed that it can move in repeatable 0.003mm increments!

[Turbo-Brown]

Phew! Bored the wonky bore to 41mm.
Will just be a bit lumpy above idle!

[Turbo-Brown]

Next up, going to try my hand at metal spinning.

Idea is to make six half donuts from aluminium, chop out a section and then weld the halves together to make a tight radius bend.

[Turbo-Brown]

So managed to make donuts today, which is good as they're the difficult bit!

Failed to make trumpets though, which is frustrating as they should be simple!

Took a few attempts to get the hang of it!

[Turbo-Brown]

Safety first!

Made trumpets today from bits of ali pipe.

Next up, welding!

Also bought the charge cooler from an M3/M4. Planning to take the plastic tanks off and fabricate replacements from more all.

[Turbo-Brown]

Welding these bends is HARD!

And I'm a terrible welder!

[Turbo-Brown]

After the disaster with sheet metal bends being too small and too hard to weld, I've decided that carbon fibre is the answer.

Making some aluminium moulds and will prepreg them

[martauto]

I really hope thats a tooling hole mate ????

Mart.

[Turbo-Brown]

Ha! I spaced those holes to line up with the slots in the bed.

Forgot to check that the toolpath wouldn't cut through a bolt aaaaaand......CRASH!

Solution: remove the bolt

[rix313]

Really cool work man. I take it the current situation means you're getting more some time to push on?

[martauto]

Ha! I spaced those holes to line up with the slots in the bed.

Forgot to check that the toolpath wouldn't cut through a bolt aaaaaand......CRASH!

Solution: remove the bolt

You could have lied and told me it was !!

Mart.

[Turbo-Brown]

Really cool work man. I take it the current situation means you're getting more some time to push on?

Yes and no, had some leave booked and the long weekend meant I got some quality garage time:-)

Hope everyone's managing to stay safe!

[Turbo-Brown]

Half a mould nearly complete

[martauto]

Now that is cool
Very few people can understand the work, effort and mostly the thought that has gone into this, not just of the moment but the numerous steps needed looking forward to produce this right now.

Mart.

[Turbo-Brown]

Cheers dude!

Took the M3/M4 charge cooler apart today,need to make a mock-up of the tanks then order material. Looks like it should be quite compact.

Also need to shift the cooler core away from the trumpet inlets.

[Turbo-Brown]

Swapped the fuel rail for an M50 one which puts the pressure regulator at the other end.

Started to fab the plenum too.
Mixture of 1.6 and 2.0mm material is much easier to weld than the 0.9mm stuff I tried to make those bends from

[Turbo-Brown]

Lots of hammering and crushing and we have two hems.

Idea is to replicate how BMW secured the tanks to the core.

[Turbo-Brown]

3 hours to fold up one piece of tin

[steve_k]

you've fat more patience than i could ever have, & the level of work is astounding.

[rix313]

And to think I got excited when I cut my first thread on my lathe the other day

[Turbo-Brown]

Thread cutting is a skill in itself!

Other end tank ready to weld on tomorrow

[Turbo-Brown]

WOW,my welding is terrible! :Lol:

Not too far from having this finished though.

[martauto]

Please dont knock it mate , you know how I feel about your abilities !!!!!

Mart.

[Turbo-Brown]

Thinking of grinding the welds flush and going over them so they look nice.....er.