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What has Dave Been Up To? 29th AUG 2015: 10.66@126.09mph!!

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dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#976390


Drilled down with a 24mm drill, and then followed through with a long slot drill,
and plunged a couple of different broach drills to plot out the ports shape.



westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#976391
For the port, the long , outside curve is cut in steps,
and for the short inside curve, and sides of the port,
the mill's head was tilted and swivelled at various angles.

This will later be finished by hand. (ie porting, not my favourite job!)





westi wrote:That's mad Alan.

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 ·

#976392
oh Dave.....

....and then you have to do it again!

Keep it up mate, thanks for the pics.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 ·

#976393
The boy with all the toys!!!😁

LOWBUG Insano Dub Head

738 posts · joined Jul 2003 ·

#976396
Holy shit, Is there enough time in a day?

Sides Veteran Volks Folk

2,220 posts · joined May 2007 ·

#976403
LOWBUG wrote:Holy shit, Is there enough time in a day?
With the lighting in the pics going from early morning, through midday and then into the dark again... I'd guess not !!!

😂

Looks awesome DB... amazed as always at what you churn out.

👍
VWDCQ vice pres & web dude - vwdcqinc.org.au
Join a car club - get car peeps

My toys
'70 Hillclimb Bug 'Jezebel' w/- Haltech EFI - http://bit.ly/VwTNtQ
'60 KG Coupe - resto kinda started
01 New Beetle - gf's car, but I turn the spanners

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#976407
LOWBUG wrote:Holy shit, Is there enough time in a day?
No, no where near enough.
Especially with work jobs as well.
At least with summer getting closer, there is a solid 12 hours of light, and I always have 400watt lights above me.
westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#976408
Sides wrote:
LOWBUG wrote:Holy shit, Is there enough time in a day?
With the lighting in the pics going from early morning, through midday and then into the dark again... I'd guess not !!!

😂

Looks awesome DB... amazed as always at what you churn out.

👍
Yes, Sundays are good for a full day on my stuff.
Unfortunately work jobs or bush walking has to take a back seat,
when you are set up in the mill for a long winded job.
westi wrote:That's mad Alan.

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#976414
going the extra mile dave, very nice! Is there any taper to the valve?
EVERLAST CONCRETE TANKS
1800 552 123

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#976417
mactaylor wrote:going the extra mile dave, very nice! Is there any taper to the valve?
Yes, gradual taper from 64mm at the top, (ram tubes style still undecided),
down to the head-flange where it matches parallel for about a half inch,
then the head will remain as it is.

My old manifolds have a small cross section inside,
that restricts the current combination to 322cfm.

Also there are cracks appearing in the old manifolds
where they are wafer thin below the butterflies.
westi wrote:That's mad Alan.

20bkombi Wolfsburg Wizard

597 posts · joined Mar 2009 ·

#976441
Hell yeah!!! Loving the pics and progress Dave, must be hard to keep focused on day jobs when these babies are set up in the mill. 👍👍
AARON'S SPEED SHIFT AUTOS
Specialising in Vw automatic transmissions, differentials and torque converters
Stock or modified to suit your application (street, drag, off road)
Ph 0402 233 027

modnrod Fahrvergnugen

978 posts · joined Mar 2011 ·

#976444
As much as I could admire your skills at work all day man, and I am, I can't help thinking that such a project may possibly be accomplished by a man with your skills, by taking that bin full of chips and swarf, then learning the fine art of making sand moulds and smelting aluminium in a bloody great pot (ala a certain kiwi who had an Indian).

Actually that's a shit idea, then we couldn't watch you have fun doing this! 👍

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978491
Throttle stops
meant I had to plunge down with a 3/16" end mill,
48 times for each one, on a 24mm pcd.











westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978492
Barrel valve mounting pad above ^ and a close up of the throttle stop below.

Then to drill for the nozzles so they come out just above the butterfly.











westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978494










westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978495










westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978496










westi wrote:That's mad Alan.

bat69 There is no status

791 posts · joined Apr 2005 ·

#978548
Those manifolds/tb are tops. I lov it but you must have waaaayy tooouch time on your hands as that would have taken you ages just to get to this point. Whats the advantage of these puppies v's something bought off the shelf?
White Knuckle Racing Team [/i]
"Drive it like dirt"

andrewmurphy Officially Full-On Dubber

307 posts · joined Jul 2005 ·

#978549
bat69 wrote:Those manifolds/tb are tops. I lov it but you must have waaaayy tooouch time on your hands as that would have taken you ages just to get to this point. Whats the advantage of these puppies v's something bought off the shelf?
The biggest advantage would be to say 'I made them myself!'

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978595
You can not buy anything like this off the shelf!
Don't worry, I tried!

The closest I could buy, was a manifold to suit IDA
and some 62 throttle bodies.

These have the potential to be bored to 76 at a later time,
and the most important thing I wanted,
was to have the butterflies close together.
westi wrote:That's mad Alan.

Smiley Veteran Volks Folk

2,125 posts · joined Oct 2008 ·

#978662
I certainly hope you don't plan on mounting these to your car!!??

They belong in an art gallery!!!

Beautiful work as always Dave, keep the pictures coming!



Smiley 🙂
If you said I was a Volkswagen man, you'd be right.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#978712






westi wrote:That's mad Alan.

HappyDaze Superannuated

2,887 posts · joined Jun 2009 ·

#978713
Ah-ha, now i know what you do in your spare time, Dave......you make swarf, and heaps of it.🙄

The gearbox is nice, by the way.
I'd rather wear a Beetle out by racing it than by polishing it!

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979319
Two days of porting and ready to bolt on:

Still have to make ram tubes though. 🙁

westi wrote:That's mad Alan.

SuperOwen Fahrvergnugen

868 posts · joined Jan 2009 ·

#979331
Very impressive! How do they compare weight wise?

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#979338
pretty but heavy dave, any plans to lighten them off?
EVERLAST CONCRETE TANKS
1800 552 123

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 ·

#979342
Wow 😵‍💫

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979343
No more lightening, have to leave material for future throat increase.
Prob a couple kilos each, less than the weight of a terminator carb.
Not that heavy actually! Less than old ones (not with the ram tubes,)
but will be heavier with the billet rams in the works at the moment.
westi wrote:That's mad Alan.

dragvw2180 Officially Full-On Dubber

393 posts · joined May 2006 ·

#979467
It would be interesting to see how much flow increase you gained by improving the port to manifold angles and if there were any turbulance changes going into the cylinders. As always Dave your work is very impressive. Mike McCarthy

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 ·

#979533
X2

I have long thought (in my own little mind) that the distance between the throttle bodes for an IDF/DRLA vs IDA spacing had some impact on the flow.