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 dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on November 28th, 2013 at 07:37 AM |
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on November 28th, 2013 at 08:07 AM |
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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!)
| Quote: | Originally
posted by westi
That's mad Alan.
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 matberry
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| posted on November 28th, 2013 at 08:07 AM |
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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
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vassy66T1
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| posted on November 28th, 2013 at 08:08 AM |
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The boy with all the toys!!!
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LOWBUG
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| posted on November 28th, 2013 at 08:20 AM |
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Holy shit, Is there enough time in a day?
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Sides
A.k.a.: Dave Sidery
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| posted on November 28th, 2013 at 10:08 AM |
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| Quote: | Originally
posted by LOWBUG
Holy shit, Is there enough time in a day?
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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.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on November 28th, 2013 at 11:14 AM |
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| Quote: | Originally
posted by LOWBUG
Holy shit, Is there enough time in a day?
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on November 28th, 2013 at 11:17 AM |
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| Quote: | Originally
posted by Sides
| Quote: | Originally
posted by LOWBUG
Holy shit, Is there enough time in a day?
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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.
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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mactaylor
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| posted on November 28th, 2013 at 04:16 PM |
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going the extra mile dave, very nice! Is there any taper to the valve?
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on November 28th, 2013 at 05:32 PM |
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| Quote: | Originally
posted by mactaylor
going the extra mile dave, very nice! Is there any taper to the valve?
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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20bkombi
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| posted on November 28th, 2013 at 10:38 PM |
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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.
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modnrod
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| posted on November 28th, 2013 at 10:50 PM |
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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!
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 23rd, 2013 at 07:30 AM |
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Throttle stops
meant I had to plunge down with a 3/16" end mill,
48 times for each one, on a 24mm pcd.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 23rd, 2013 at 07:33 AM |
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 23rd, 2013 at 07:38 AM |
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| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 23rd, 2013 at 07:42 AM |
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| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 23rd, 2013 at 07:45 AM |
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| Quote: | Originally
posted by westi
That's mad Alan.
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bat69
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| posted on December 23rd, 2013 at 05:59 PM |
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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
"Drive it like dirt"
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andrewmurphy
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| posted on December 23rd, 2013 at 06:12 PM |
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| Quote: | Originally
posted by bat69
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?
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The biggest advantage would be to say 'I made them myself!'
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 24th, 2013 at 05:07 AM |
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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Smiley
A.k.a.: Daniel Stephens
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| posted on December 25th, 2013 at 11:45 AM |
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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.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on December 26th, 2013 at 02:50 PM |
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| Quote: | Originally
posted by westi
That's mad Alan.
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HappyDaze
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| posted on December 26th, 2013 at 03:16 PM |
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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!
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on January 1st, 2014 at 05:04 PM |
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Two days of porting and ready to bolt on:
Still have to make ram tubes though. 
| Quote: | Originally
posted by westi
That's mad Alan.
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SuperOwen
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| posted on January 1st, 2014 at 06:08 PM |
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Very impressive! How do they compare weight wise?
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mactaylor
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| posted on January 1st, 2014 at 07:30 PM |
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pretty but heavy dave, any plans to lighten them off?
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hellbugged
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| posted on January 1st, 2014 at 08:10 PM |
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Wow 
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on January 1st, 2014 at 08:16 PM |
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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dragvw2180
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| posted on January 3rd, 2014 at 12:23 PM |
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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
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vassy66T1
A.k.a.: Marcus Vass
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| posted on January 4th, 2014 at 10:43 AM |
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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.
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