Time to go Stage II!
- Thread starter Alky V6
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Squid4life
Well-Known Member
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Donnie, are you talking about cutting/milling the SS, or welding it? I have read any kind of milling on SS is pretty tough...
Cutting and milling. I should have just sent this job to the waterjet shop, but I didn't want to take the chance of having to wait for them to get to it, so I cut them out with a combination of a horizontal bandsaw, cutting wheel and cutting disc. I gave up on the bandsaw pretty quick. Once I got the flanges cut into individual pieces, I squared up the main straight edge outline of the pieces with the milling machine. That wasn't too bad, but the bit will definitely need to be sent out for sharpening after this job.
Now I'm going to take care of the holes in the flanges, then I'll worry about rounding the corners of the outer edges.
I made my own aluminum adapters. I posted pics of them. What I'm working on now are the header flanges.
I've been waiting for the exhaust flanges to get back from the CNC machinist. While doing that, I've been playing with the new upgraded engine sim. Tweaking this and that, and came up with a new projected graph for the project.
This is using a 4.5:1 a/f ratio, which is good for power, but very lean for this projected power level. To run this lean of an a/f ratio at this performance level, while staying away from preignition territory, will require an intercooler efficiency of around 80%.
Though this graph doesn't show it, the power curve does not begin to significantly drop off until after 9,250 rpm.
This is using a 4.5:1 a/f ratio, which is good for power, but very lean for this projected power level. To run this lean of an a/f ratio at this performance level, while staying away from preignition territory, will require an intercooler efficiency of around 80%.
Though this graph doesn't show it, the power curve does not begin to significantly drop off until after 9,250 rpm.
One flange is finished. In the picture the flange is fitted to the adapter with allen capscrews. The plan is to use 12 point flange bolts in the final assembly.
The new sander made the finishing a breeze. The wonders of power tools.
The new sander made the finishing a breeze. The wonders of power tools.
The next step is to weld the stubs to the exhaust header flanges.
Each stub will have a taper to them, and will mount to each flange with a 7 degree up angle, following the same taper and path started through the adapter and the flange.
The one inch section marked on this transition pipe will be cut out and will be used as the stub.
The step after fabricating the stubs will be starting to get into the exciting stuff. Yippee! I'll be fabricating a new tripod support for the 91mm turbo. The plan is to mount the turbo in exactly the same position as I had with the Stage I configuration. After the turbo is hung, I'll fabricate the 'Y' pipe that will feed the turbo.
Each stub will have a taper to them, and will mount to each flange with a 7 degree up angle, following the same taper and path started through the adapter and the flange.
The one inch section marked on this transition pipe will be cut out and will be used as the stub.
The step after fabricating the stubs will be starting to get into the exciting stuff. Yippee! I'll be fabricating a new tripod support for the 91mm turbo. The plan is to mount the turbo in exactly the same position as I had with the Stage I configuration. After the turbo is hung, I'll fabricate the 'Y' pipe that will feed the turbo.
278cikiller
Active Member
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- Dec 21, 2007
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Are you kidding me Donnie! Do you work for NASA on the side... lol.
SCOOBY DOO
BASED CANADIAN PATRIOT!!
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- Feb 18, 2007
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Keep the pics comin' Donnie.
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