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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 ·

#979536
Time to make the ram tubes now.
Started with 2 chunks of 100 square 6061 x 185 long.

Rough bored the throats to 50mm and put in the bolt holes:



By tilting the bores at 5 degrees, I should be able to get a full 10mm radius in top.

westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979538
Set up in the vice and bore holes from both sides to 64 diameter,
leaving a 10mm wide ledge inside
for clamping onto a mandrel for later machining operations.



Turned up a mandrel from 70 diameter steel, and drilled and tapped a hole M10 in the end.
A 10mm thick washer, and type 1 ring gear bolt holds it in place:



I can then taper turn the bore and face it square:



Bore tapers from 68 down to 64mm which is 4 degrees included angle.

westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979540
The next step was to modify the mandrel to go onto the rotary table.
I used a VW 10mm head stud to clamp the whole deal down,
so I could still rotate it:



I used a 10R corner rounding tool, and once the position and depth were sorted,
it was just a matter of cranking the handle.





westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979542


Final steps were to radius all the corners with 5r tool,
mill out the sides for bolt access and clearance, and final step was to bore out the ridge that was left inside:









westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979543
westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#979544
vassy66T1 wrote: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.
That is exactly why I chose to 'make' instead of 'buy'.
westi wrote:That's mad Alan.

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 ·

#979649
Very, very clever work on the ram tubes!

I might have to go for a drive this week to see this in the flesh 🙂

LIFE IN THE LOW LANE All people have the right to stupidity but some abuse the pr

2,534 posts · joined Mar 2007 ·

#979658
Everything is getting bigger so it might be time to step up to a softball to replace the tennis balls lol

Salubrious dude!! Look awesome!!
ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE

Alder Outlaws VW Racing - check it out on fb!!

matberry Moderator Go hard or go home

8,114 posts · joined Mar 2006 ·

#979660
^^ lol

Huge effort Dave. Top job
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE

Sides Veteran Volks Folk

2,220 posts · joined May 2007 ·

#979679
Looks frikken awesome DB !!!

Curious about the finish... have you given them a light blasting, or is just the pics ?
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 ·

#979729
Sides wrote:Curious about the finish...
Just gave them a buff with a fresh wire wheel.

Probably go over the radii with a flap wheel,
and buff again at final assy.
westi wrote:That's mad Alan.

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#979762
nice dave, nice.
EVERLAST CONCRETE TANKS
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RISKY4LIFE Officially Full-On Dubber

308 posts · joined Jul 2010 ·

#980946
lol yeah you might need bigger balls 😀

tassupervee That really hurts doesnt it!

1,171 posts · joined Sep 2003 ·

#983510
Good to see your still tinkering with different intake setups Dave.. and everything else Id be guessing knowing you!!!

E
Im not a complete idiot, quite a few parts are missing....

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#985653
Final flow test resulted with 334cfm @ 25".
Previously it was 322.



westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#985656
Next step is to make some new barrels.











westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#985657












westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#985658














westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#985659
Just need to bore and hone the final .030" to size.



westi wrote:That's mad Alan.

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 ·

#985660
Nice work!!
Do you think the cylinders are structural enough to resist distortion? 🙄

Grey Ghost Casual Dubber

38 posts · joined Feb 2011 ·

#985666
Hi Dave was there any special grade of material that you used for the cylinders? Are the steel grades in these like those of diesel liners? Very nice machining work as usual!
Cheers
Andrew
Andrew Ermel

modnrod Fahrvergnugen

978 posts · joined Mar 2011 ·

#985667
Mmmm........VERY thick cylinders.
No possible chance of splitting for any reason.
You considering blower/boost/bottle again Dave?
👍

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#985675
Andrew, the grade of cast iron is called 2P.
I have made a few different styles of cylinders over the years, and always this material was best.

I have used diesel(hino 96mm bored to 100mm) liners before,
and to machine, it is similar.
I made these ones extra thick to keep them round in the bore.

Even with my old thin ones, they stayed very round, until it was just a little lean.
Car went quicker when leaned off,
but leak down test and subsequent measuring showed them to go out of round at the top.(about 3.5mm wall)

I have never split a cylinder in my life.
Even when 42psi boosted,
but, no, for these, not going for boost again.

ps, I did have a carrillo rod go through a cylinder once however!
westi wrote:That's mad Alan.

modnrod Fahrvergnugen

978 posts · joined Mar 2011 ·

#985719
dangerous wrote:ps, I did have a carrillo rod go through a cylinder once however!
Wouldn't be a VW if it didn't leak occasionally! 😂

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#986317
westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#986319
Always more to do when you look a little closer!







westi wrote:That's mad Alan.

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#986367
exhaust side of the intake port?
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dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#986383
No, just tidying.
That inside curve(exhaust side) is convex on purpose.
westi wrote:That's mad Alan.

modnrod Fahrvergnugen

978 posts · joined Mar 2011 ·

#986384
Are you biasing the flow to swirl towards the plug better?

I've often thought that for a little streeter, like a 1584, there's more to be gained in part-throttle torque/economy/response by focussing on port bias than correctly calculated port size/volume.

Enough of my fluff!
Love your pics and write up Dave, more please. 👍

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#986397
No David, just away from the bore wall.
Genuine VW heads do this pretty well already.
westi wrote:That's mad Alan.