tooter's manifold adventure...

[tooter]

The flange and throttle body adaptor will both be ready to pick up on Thursday. (goody)

Here's a video of the CNC machine making the flange...

http://www.youtube.com/watch?v=yVkFs7PlMVc

This is so exciting to watch the part being made!

Those numbers flowing down the lcd screen are the running stream of thousands of X and Y coordinates which locate the milling bit which is accurate to .0005 inch and can exert force of up to 2,000 pounds. The load graphs show minimal total spindle loading of about 3%. The part takes about 4 hours to manufacture. I'm going to try to get the parts to the welder as quickly as possible, and may have the manifold on the engine this weekend.

[Bluevitz-rs]

^Your link is bad... It just brought me to my OWN youtube video page.

[tooter]

Try it now. The link is outside of my account.

[malibuguy]

awesome

[tooter]

Here's closeups of the ports taken while it was being flipped over to finish off the bottom.







The machine ran at a very fine resolution making lots of passes so that the transitions are nice and smooth.

[Bluevitz-rs]

Cool. I miss my tool and die days sometimes. Took it in school and never found a job that would pay a decent wage.

[3cyltrbo]

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Tooter for President???

anxiously awaiting the final piece and dyno results

Big ups and much respect (as Alli G would say)

Will

[tooter]

Originally Posted by 3cyltrbo

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Tooter for President???

anxiously awaiting the final piece and dyno results

Big ups and much respect (as Alli G would say)

Will

Thanks for your kind words, Will.

I don't expect much from the second dyno as the stock Toyota manifold is factory engineered to be highly specialized for the 1NZ-FE. Whereas I'm just adapting something to an unintended purpose.

The OEM manifold does have quite a large plenum area... and that's good.

...because while the Corolla manifold has larger runners, the plenum area is quite small. This helps to make the total volume of the manifolds more equal to each other.

When I get the new manifold assembled, I'm going to tape off one end of both manifolds and fill them both up with water. Then I'll pour each one out into a big measuring cup and log each volume just to see how close they are.

I get really curious about funny stuff like this...

[CrankyOldMan]

Will you be polishing the insides?

[tooter]

Hey Cranky,

Hadn't even thought about that. But I doubt it, maybe just hit them with a little fine emery cloth since I'm not running a top fuel dragster.

Did you notice anything about the outside runner holes?



We didn't undercut them as it would have added even more cost to the job. You had mentioned that as an issue, and we took the easy way around it...





The inner edges of the outer runners go straight down the edge of the head with no inner ledge. I'll simply feather out the inside edge of the runner tubing with a Dremel since the affected area is so small.

You should be able to the same thing to yours with no problems.

[CrankyOldMan]

Originally Posted by tooter

Hey Cranky,

Hadn't even thought about that. But I doubt it, maybe just hit them with a little fine emery cloth since I'm not running a top fuel dragster.

Did you notice anything about the outside runner holes?


We didn't undercut them as it would have added even more cost to the job. You had mentioned that as an issue, and we took the easy way around it...

The inner edges of the outer runners go straight down the edge of the head with no inner ledge. I'll simply feather out the inside edge of the runner tubing with a Dremel since the affected area is so small.

You should be able to the same thing to yours with no problems.

Interesting. I was wondering how you would get around that. I had also considered something like that but with additional metal being added (welded) to that edge on the inside to meet the rim of the runner. Looks like it's coming along nicely, still can't wait to see how it performs!

[tooter]

Originally Posted by CrankyOldMan

Interesting. I was wondering how you would get around that. I had also considered something like that but with additional metal being added (welded) to that edge on the inside to meet the rim of the runner. Looks like it's coming along nicely, still can't wait to see how it performs!

Seeing how the adaptor actually turned out with such a small area with no ledge, it's really not much of an issue. I'll just knock the edge off from the inside.

[anomoly40]

Are you planning on annodizing that intake?

[tooter]

Originally Posted by anomoly40

Are you planning on annodizing that intake?

No... but that's just my own personal preference. I don't much care for the shiny plastic "circus" look of anodized aluminium.

But something will definitely need to be done to "normalize" the appearance of a brand new machined intake flange and throttle body adaptor on a beat up 14 year old junkyard manifold!

I'm thinking more like sandblasting the whole thing (except for the milled gasket surfaces) so that all of the surfaces will assume the same aluminium color and texture. After that, I don't know. Right now, I'm focused on finding out if the damn thing works first.

[anomoly40]

Look into Dust annodizing. I play paintball often and there are some amazing things they can do with anno.

Also Type 3 Anno doesn't have the plasticy look to it. It also helps with Heat disapation.

[malibuguy]

Effing tits flange

[tooter]

It actually ~could~ have had tits on it...
The CNC guy said that there's software with such fine image resolution that with the right bit, the machine could replicate the head on a quarter.

[anomoly40]

We have a 1/64" endmill at work. We ordered it by accident. Even crazier is that they make smaller ones.