Twin Seq. Dry sumping for beginners :D

[rix313]

WOW,my welding is terrible! :Lol:

Not too far from having this finished though.

Says the guy who has cast and machine his own throttle bodies haha, I don't know any welders who could achieve that

[martauto]

WOW,my welding is terrible! :Lol:

Not too far from having this finished though.

Says the guy who has cast and machine his own throttle bodies haha, I don't know any welders who could achieve that

Proper Engineer

Mart.

[Turbo-Brown]

Had to sort out a room for one of the weiners so not made any progress of late.

Did manage to machine the slots for the turning vanes into the plenum today though

Health Robinson set up with 123 blocks and G-clamps but worked out okay.

Will make the vanes next and weld them in

[Turbo-Brown]

Turning vanes made, time to break out the tiggy torch!

[rix313]

I assume you have a metal folder stashed away somewhere to make such neat folds?

[Turbo-Brown]

I wish!

Did all the folding using G-clamps,strips of metal and a hammer

Turning vanes welded on fully,even managed a couple of reasonably neat welds.....plus some lumpy bilge!

Need to finish welding and pop a dump valve boss on and this one's done!

[martauto]

I have no idea what this does but the effort and thought that has gone into it is so special, top draw again mate

Mart.

[Turbo-Brown]

It fits!!!
My fabrication actually fits!
Going to machine a simple fixture to hopefully prevent warping and weld up the rest of it then start the other end tank.
Need to finish the dump valve by machining away all the excess material and sorting its seals too.

[Turbo-Brown]

Need to make mock-up trumpets to confirm they fit before I ask someone to make them in carbon.

Also need an accurate mock-up so I can build the other tank for the charge cooler.

[Turbo-Brown]

Only half a trumpet to go!

[rix313]

It fits!!!
My fabrication actually fits!
Going to machine a simple fixture to hopefully prevent warping and weld up the rest of it then start the other end tank.
Need to finish the dump valve by machining away all the excess material and sorting its seals too.

Thats really cool man, great work

[Turbo-Brown]

Hooray,this side is finished!

Made bosses for the dump valve and idle air, might need a couple of mounting bosses still.

Amazed it didn't warp! Glad I made the fixture for it!

Now for the other tank!

[martauto]

That should be like a banana !!!!!

Great stuff this but still dont know what it is lol

Mart.

[Turbo-Brown]

Here's beer and the fixture,so glad I made these!

Fixture was just a groove machined into a lump of tooling plate to hold the sides true.

[Turbo-Brown]

Slow progress of late, doing lots of measuring and adjusting to make sure the trumpets will fit!

If I can get the mould modified this week they might be made by the end of August!

[Turbo-Brown]

The thing that looks like a metal slug is the inlet to the charge cooler from the turbos.
Need to machine some slots in the tank and slug then weld them together.

Dangerously close to having the charge cooler finished!

[martauto]

Wow, is there no end to your talents ???

Welding Aly ??
Wish we had an up-date every day.

Mart.

[Turbo-Brown]

Won't post any close up images of my welding, it's shocking!

[martauto]

Look through the "mess" and true beauty is there

Mart.

[Turbo-Brown]

Decent progress today, that tank is nearing completion!

[rix313]

What will you be doing for heat shield and heat protection for the inlet?

[Turbo-Brown]

I'm going to weld some tapped bosses on, then wrap the tank in ceramic fibre insulation and bolt a thin Ali sheet over to hold the insulation in place.

Should prevent exhaust heat from raising inlet temperatures too much I think.

The electric furnace I made is insulated with 25mm of ceramic fibre. It's cooking away at over 750C inside and is still cool enough to touch on top.

[Turbo-Brown]

Welding done, needs a skin flat and to reduce the wall thickness a mm each side then we're good to go!

Got my genuine Bosch Motorsport primary injectors this week which solve a clash with my trumpets.

Once that's bottomed out I can modify the trumpet mould and give it to my friend the laminator

[Turbo-Brown]

Modified the first tank to clear the bonnet better.

Also forgot the inlet air temperature sensor so added a boss for that.

Need mounting bosses now and to make a tool to crimp the tanks to the core and we're done!

[Turbo-Brown]

Making the crimping tool to attach the tanks to the core now.

Have fabricated a crude vice thingy and am now machining the jaws parallel.

Also needed to machine the interface between the inlet tank and the core.
That'd be okay if I'd thought to block up all the internal cavities and passages....but I didn't and so can't get in there to clean now!

Have ordered some sodium hydroxide so I can hopefully dissolve any chips, just have to make sure I don't dissolve the tank!

[Turbo-Brown]

That worked well, look how clean it is inside!

[Turbo-Brown]

Woo hoo, charge cooler is finished!

Can now modify the inlet trumpet mould and see if my mate's free to make them for me.

After that, insulation and brackets for the cooler.

In the mean time,been working on the actuators for the valves and traction control

[Turbo-Brown]

Been doing some prototyping for the actuators of late.

Last setup proved the concept,and demonstrated that more sensors are needed and they need to be accurately positioned around the shaft.

So I milled out a PCB to hold the little sensors.

The sensors are SS49E from Honeywell, they're linear hall sensors which give out a signal proportional to magnetic field strength.

On the shaft is a diametrically magnetised ring magnet which the sensors read, here's the output trace as the shaft rotates.

So just got to make sense of the readings so that I can close the loop for these little servo motors.

[martauto]

I understand the beer and thats all !
Apart from the engineering side of it lol

Mart.

[chatstar123]

I've been keeping an eye out for updates on this thread and can't wait to see the finished article. Keep up the good work!

[Turbo-Brown]

Work on the actuator code is going well,can now determine the angle of the output shaft

Started working on the PID loop so that the shaft rotates to a commanded angle. This was going well, until I got a bit enthusiastic with one of the tuning parameters and blew up the motor drive

Have popped a few drives now and can't do any more development until more arrive from China.

So in the mean time, brackets for the charge cooler!

Reusing bits of bracketry that came with the cooler which looks more professional than I can manage

[Turbo-Brown]

Finished off the charge cooler brackets, hooray!

Not exactly works of art but rigid enough.

Now the cooler is properly supported,can finally commit to getting the inlet trumpets made!

Need to chop a massive amount off the mould!
Got to cut it down to the Sharpie line!

[Turbo-Brown]

Exciting!
Been working on the trumpet mould again, it's nearly ready!
Chopped down to length,made some bolsters for the trumpet end, just need to machine a register for the trumpet part of the mould.

Will make a couple of dummy trumpets as a final fit and function check then it's off to pre-preg!

[martauto]

Whats pre-preg ??
Love the cute boring head, a very rare sight these days unfortunately.
Great work mate

Mart.

[Turbo-Brown]

Pre-preg is a reinforcement, such as carbon fibre, that's been pre impregnated with resin.

It's what the vast majority of carbon bits are made using as it's clean(ISH) to use, can be accurately cut to shape before putting in the mould and, most importantly, allows accurate control over the ratio of fibre to resin.

Almost ready to go now!

Used the diddy boring head as a variable diameter end mill so I could get this little step machined accurately.