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 dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on January 4th, 2014 at 10:47 AM |
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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.
| 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 January 4th, 2014 at 10:53 AM |
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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.
| 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 January 4th, 2014 at 10:58 AM |
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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.
| 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 January 4th, 2014 at 11:02 AM |
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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:
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on January 4th, 2014 at 11:03 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
23 Windows of Awesome
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| posted on January 4th, 2014 at 11:08 AM |
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| Quote: | Originally
posted by vassy66T1
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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That is exactly why I chose to 'make' instead of 'buy'.
| Quote: | Originally
posted by westi
That's mad Alan.
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vassy66T1
A.k.a.: Marcus Vass
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| posted on January 5th, 2014 at 07:45 AM |
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Very, very clever work on the ram tubes!
I might have to go for a drive this week to see this in the flesh 
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LIFE IN THE LOW LANE
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| posted on January 5th, 2014 at 08:42 AM |
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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!!
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
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 matberry
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| posted on January 5th, 2014 at 08:49 AM |
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^^ lol
Huge effort Dave. Top job
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Sides
A.k.a.: Dave Sidery
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| posted on January 5th, 2014 at 01:07 PM |
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Looks frikken awesome DB !!!
Curious about the finish... have you given them a light blasting, or is just the pics ?
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on January 5th, 2014 at 07:13 PM |
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| Quote: | Originally
posted by Sides
Curious about the finish...
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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.
| Quote: | Originally
posted by westi
That's mad Alan.
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mactaylor
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| posted on January 6th, 2014 at 02:01 AM |
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nice dave, nice.
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RISKY4LIFE
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| posted on January 18th, 2014 at 05:44 PM |
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lol yeah you might need bigger balls 
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tassupervee
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| posted on February 16th, 2014 at 11:41 AM |
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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....
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 11th, 2014 at 09:08 AM |
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Final flow test resulted with 334cfm @ 25".
Previously it was 322.
| 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 March 11th, 2014 at 09:24 AM |
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Next step is to make some new barrels.
| Quote: | Originally
posted by westi
That's mad Alan.
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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on March 11th, 2014 at 09:30 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
23 Windows of Awesome
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| posted on March 11th, 2014 at 09:35 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
23 Windows of Awesome
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| posted on March 11th, 2014 at 09:38 AM |
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Just need to bore and hone the final .030" to size.
| Quote: | Originally
posted by westi
That's mad Alan.
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vassy66T1
A.k.a.: Marcus Vass
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| posted on March 11th, 2014 at 09:59 AM |
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Nice work!!
Do you think the cylinders are structural enough to resist distortion? 
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Grey Ghost
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| posted on March 11th, 2014 at 11:37 AM |
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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
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modnrod
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| posted on March 11th, 2014 at 11:43 AM |
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Mmmm........VERY thick cylinders.
No possible chance of splitting for any reason.
You considering blower/boost/bottle again Dave?
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 11th, 2014 at 03:26 PM |
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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!
| Quote: | Originally
posted by westi
That's mad Alan.
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modnrod
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| posted on March 11th, 2014 at 09:41 PM |
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| Quote: | Originally
posted by dangerous
ps, I did have a carrillo rod go through a cylinder once however!
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Wouldn't be a VW if it didn't leak occasionally! 
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 18th, 2014 at 10:14 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
23 Windows of Awesome
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| posted on March 18th, 2014 at 10:19 AM |
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Always more to do when you look a little closer!
| Quote: | Originally
posted by westi
That's mad Alan.
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mactaylor
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| posted on March 18th, 2014 at 07:23 PM |
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exhaust side of the intake port?
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 18th, 2014 at 09:13 PM |
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No, just tidying.
That inside curve(exhaust side) is convex on purpose.
| Quote: | Originally
posted by westi
That's mad Alan.
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modnrod
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| posted on March 18th, 2014 at 09:44 PM |
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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. 
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on March 19th, 2014 at 06:07 AM |
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No David, just away from the bore wall.
Genuine VW heads do this pretty well already.
| Quote: | Originally
posted by westi
That's mad Alan.
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