GSlender's Track Beeotch!

plohl · Postby **plohl** » Tue Sep 09, 2014 9:37 am

The billet you would need wouldn't be too expensive (something of similar, but smaller size was ~$100 in 6061 from Action Aluminum last time I bought some). It's not complicated to machine but you have to remove a lot of material which is pretty wasteful. I doubt it would be cheaper than getting some plate laser/waterjet cut, folded and welded. Still, would be interesting to see if you went down the billet path.

3d printing isn't a bad route, but it can be expensive. You may need to coat it with something to seal it. I know SLS products tend to breath a fair bit.

Magpie · Postby **Magpie** » Tue Sep 09, 2014 11:55 am

I was thinking of asking for a quote for some quick prototyping (3d printing) of some curved trumpets.

gslender · Postby **gslender** » Tue Sep 09, 2014 12:21 pm

plohl wrote:I doubt it would be cheaper than getting some plate laser/waterjet cut, folded and welded.

Folded? Do you know if you can get Aluminum folded like paper, so the welding is reduced - ie like a box, where you cut a paper into a shape that can be folded so that there is only 4 sides to weld?

I'm also wondering about just simple tin sheet, and solder/brazing coupled with a thicker backing plate that gives the trumpets something solid to mount against. The box shape with be strong just because it is solded as a box, and the lid can be bolted onto it with clips etc.

A few options for making it and I'm investigating the Aluminum billet and if that's not an option, then I'll proceed with Aluminum cut panels and welding, and if that too costly or complicated then I'll just play around with tin and brazing... and finally might just muck around with balsa and fiberglass etc...

Magpie · Postby **Magpie** » Tue Sep 09, 2014 12:29 pm

G I have a metal folder, will do:
915mm Width
20mm Press Volume
120º Max Bending Angle
2mm Max Folding Capacity

If you want to visit and use it your welcome. We will be moving to Purga and will be there in a few weeks

plohl · Postby **plohl** » Tue Sep 09, 2014 12:41 pm

gslender wrote:Folded? Do you know if you can get Aluminum folded like paper, so the welding is reduced - ie like a box, where you cut a paper into a shape that can be folded so that there is only 4 sides to weld?

Yeah. It's pretty common for sheet metal products. Obviously some tooling is required for more complex shapes which can increase the cost. Check out Danny's NC, there is a bunch of mad sheet metal fab in that.

Magpie · Postby **Magpie** » Tue Sep 09, 2014 2:52 pm

In addition to the metal folder I have a manual bar bender (max 100mm x 5mm) up to 120° that can do small radius bends in bar as well as air nibblers, other air tools for metal work, rivets and nut sets. This stuff is what I'm planning to use for my radiator duct etc.

If I can help you build yours, maybe we can build 2 at the same time

gslender · Postby **gslender** » Sat Sep 13, 2014 9:38 am

Turns out I need a fair number of new shims after the head had the valve grind etc. Probably something that should have been done by the guys that did the head, but meh, no big deal.

So, these are all the shims I need to order...

3 27.00mm Flat Shims Size: 3.36mm
1 27.00mm Flat Shims Size: 3.46mm
1 27.00mm Flat Shims Size: 3.34mm
2 27.00mm Flat Shims Size: 3.44mm
3 27.00mm Flat Shims Size: 3.42mm
1 27.00mm Flat Shims Size: 3.52mm
1 27.00mm Flat Shims Size: 3.32mm

Surprisingly I only was able to re-use/redeploy 4 of the existing shims

G

plohl · Postby **plohl** » Sun Sep 14, 2014 9:15 am

It's probably Nigel's fault...

gslender · Postby **gslender** » Sun Sep 14, 2014 1:14 pm

plohl wrote:It's probably Nigel's fault...

It's always Nigel's fault !!

gslender · Postby **gslender** » Sun Sep 14, 2014 10:17 pm

Got bored waiting for parts so decided to black the A pillar and windscreen frame - ND style....

Need to attack the side mirrors and it will look complete.

A black roll bar will complete the look me thinks!

Sent from my iPhone using Tapatalk

gslender · Postby **gslender** » Mon Sep 15, 2014 1:48 pm

Question - should I paint the silver mirror back (rounded cover panel) in black AND the silver door mirror mount? or just the rounded cover panel?

I'm thinking I could just paint the back of the mirror rounded cover panel initially (and see how it looks) and if needed, the door mount later. Just not sure and would like to see it before I mask up etc....

Mmmmm ???

G

Magpie · Postby **Magpie** » Mon Sep 15, 2014 9:27 pm

Buy some new ones, you should never stop buying parts!

gslender · Postby **gslender** » Sun Sep 21, 2014 8:53 pm

New shims in, and camshaft / head all back together. Engine started and she sounds heaps better.
Job wasn't that hard and longest part was waiting for the new shims.

Now to take it for a spin and see if 6,000 rpm sounds better etc... I'm thinking it will but will know soon I guess.

G

gslender · Postby **gslender** » Wed Sep 24, 2014 2:42 pm

Complete a drawing of the ITB airbox I need to have created. I can now go and talk to various folks about how best to build/create. Hopefully not too complex !!

http://mx5cartalk.com/forum/download/file.php?id=13119