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Everyone knows that a Z flows better than an S........ But this is all still just words, opinions, ideas, and dreams ! Time to start cutting and hope the welder can glue it back together.
“...if it weren’t for that horse, I’d never had that year in college...” what?
Everyone knows that a Z flows better than an S........ But this is all still just words, opinions, ideas, and dreams ! Time to start cutting and hope the welder can glue it back together.
My thoughts exactly but If I wrote this, would have gotten another infraction from the moderator for being an a$$hole.
Two cheater cut angle? Even worse. I was giving you the benefit of the doubt with two non-cheater turns. Like an S, or rather an integral sign (esh).
that would be a challenge to do a nice "S", but thats a talll order for this project. i think its going to just come out of the plennum area and angle down. ether way, MUCH bettter than the stock set up, even with some "cheater S" design. hey, i dont really know what its going to look like, but i do think we can make it work
Originally Posted by James Bailey
Everyone knows that a Z flows better than an S........ But this is all still just words, opinions, ideas, and dreams ! Time to start cutting and hope the welder can glue it back together.
thats the plan.. probably chopping up the 944S2 intake this weekend. what tool should i use.. band saw or cut off wheel?
that would be a challenge to do a nice "S", but thats a talll order for this project. i think its going to just come out of the plennum area and angle down. ether way, MUCH bettter than the stock set up, even with some "cheater S" design. hey, i dont really know what its going to look like, but i do think we can make it work
thats the plan.. probably chopping up the 944S2 intake this weekend. what tool should i use.. band saw or cut off wheel?
This made me chuckle, but I was thinking that using a hack saw would be more appropriate. I've had one in my tool chest since I was 17, they're cheap and cut metal at a controllable rate in tight places. Far better then a band saw or cut off wheel, and don't require learning new skills.
__________________
George
90 S4 Grand Prix White (Murf #5 - 210 mph top speed)
94 GTS 5-Speed Midnight Blue
06 Cayenne S Havanna/Sand Beige (PASM) http://928.jorj7.com
my car was built with a hack saw! (and an axe) .... i should explain, the axe was my first pass at the clutch adjustment hole for the INT plate. (pic attached for which greg made his initial comment)
however, you know what, it works.... and so did the "pins" i drilled and placed in to the "H"s. 6 years later , and still holding, clutch works perfectly. hard to argue with success. if the intake works, i could care less what it looks like.
This is the 21st century. There are things like plasma arcs, and TIG welders. Work smart not hard! Plus they're really affordable now too.
you think you want to use a plasma cutter for that little clutch peep hole? what would you use for taking the legs off the 944S2 intake and the runners off the AMV8 intake?
a cut off wheel might work just fine. i think heat at this stage might be overkill and make a mess of things.
can you guys get serious here and help. the axe joke was funny, but im starting this project and could use some help.
you think you want to use a plasma cutter for that little clutch peep hole? what would you use for taking the legs off the 944S2 intake and the runners off the AMV8 intake?
a cut off wheel might work just fine. i think heat at this stage might be overkill and make a mess of things.
can you guys get serious here and help. the axe joke was funny, but im starting this project and could use some help.
Mark,
I use a plasma arc to cut Aluminum,sheet metal fast and clean. So fast the sheet metal doesn't warp. As far as the Aluminum casting, you'll have to make a template of how you want to cut it so you can follow the shape you desire. There will be little to no clean up afterwards. The cut off wheel will leave debris, and it'll get hotter than hell. With a plasma arc, your time will be spent doing the layout, the arc will cut it out perfectly in seconds. It's impossible to get that kind of fit and precession with saws or wheels. Make a keyway for the intake flanges to match up to the runners, then clean with acetone and preheat it to weld it up. Tack welding is critical. Carbon Tet, is the best liquid cleaner, but it's banned by the EPA, in this country. I'd purge weld the runners to the flanges. That way the welds inside of the runners will look exactly like the welds on the outside.
FWIW, I've only been a certified welder for 60 years. Got just about every cert there is, aircraft, nuclear containment, pressure vessels and pipe. Taught welding and fabrication at the collage level for years. I'm not being a smart ***, just letting you know what will work out best. Plus a side benefit is you'll learn some new skills that you'll have forever.
Use a hacksaw, it's as simple as that. Yes,it takes more time than a sawsall or a bandsaw but is easily controllable and simple to use. I've used a hacksaw several times this year cutting pipes and hardly takes any time. Cutting aluminium is easy.
Now no more excuses and start cutting.
Use a hacksaw, it's as simple as that. Yes,it takes more time than a sawsall or a bandsaw but is easily controllable and simple to use. I've used a hacksaw several times this year cutting pipes and hardly takes any time. Cutting aluminium is easy.
Now no more excuses and start cutting.
ok then, ill start doing the cuts i need to do, so i can start sizing up what the end cuts will be.
Originally Posted by polecat702
Mark,
I use a plasma arc to cut Aluminum,sheet metal fast and clean. So fast the sheet metal doesn't warp. As far as the Aluminum casting, you'll have to make a template of how you want to cut it so you can follow the shape you desire. There will be little to no clean up afterwards. The cut off wheel will leave debris, and it'll get hotter than hell. With a plasma arc, your time will be spent doing the layout, the arc will cut it out perfectly in seconds. It's impossible to get that kind of fit and precession with saws or wheels. Make a keyway for the intake flanges to match up to the runners, then clean with acetone and preheat it to weld it up. Tack welding is critical. Carbon Tet, is the best liquid cleaner, but it's banned by the EPA, in this country. I'd purge weld the runners to the flanges. That way the welds inside of the runners will look exactly like the welds on the outside.
FWIW, I've only been a certified welder for 60 years. Got just about every cert there is, aircraft, nuclear containment, pressure vessels and pipe. Taught welding and fabrication at the collage level for years. I'm not being a smart ***, just letting you know what will work out best. Plus a side benefit is you'll learn some new skills that you'll have forever.
Great info. ive used a large plazma welder for fun when we cut the top off of a 928, and then cut out the cage. it was amazing how fast it cut. it was a pretty broad cut, so it makes me wonder if we had too big of a plama system to do what im thinking of doing with the intake. how much does one cost and do you have any recommendations? i suppose i need a tig welder too. i sure would hate to destroy everything, in this process practicing, but maybe i can get good enough so that i can at least make the parts fit and tack them together for then a pro to do the final welds.
I remember seeing all sorts of welding systems at harbor freight for very reasonable prices.
Mark,
You're Community Collage should have a certified welding program, and they'll have everything you'll need, plus the instructors to teach you. Aluminum welding is an art, and requires a lot of practice to master the technic.
I don't have a clue about the welders at Harbor Freight. My stuff is old, Miller, Lincoln, and Esab. I do have a Cebora Sound Mig double pulse inverter, Italian Mig Welder that is manufactured for Ferrari, to weld aluminum panels on the production line and for panel repairs. 10 years ago it was 26K at the SEMA Show, and I can hook it up to Ferrari's web site and download the Welding Parameter's and procedures. My wife about died when she found out how much I paid for it.
My first choice would be taking a class at the CC, then if that's not practical, buy a used machine. The internet is full of them, or check with the local welding supply houses like Airgas,Praxair, etc. If you're gonna do TIG welding, you'll need the shade made for tig, it's different than Mig, or Arc welding, it's blue not green. Plasma Arcs, or cutters as they're called, are ether conventional and High Definition. Depends what you want the machine to do. You should be looking for a conventional machine. HD, is for minimal dross, larger applications, continuous duty cycle machines in production. Lincoln makes fantastic machines for the home garage.
You'll also need a constant supply of compressed air. Plasma machines use lots of air. Plus there are different backing gases used in welding, and it depends on the base metal. There's going to be a BIG DIFFERENCE between the Aluminum, used by Porsche, and Aston Martin. You'll have that to contend with too. The correct Tungsten is critical, you'll have to learn to read you're Tungsten tips, red or green band, lanthanated or thoriated.
I'm not trying to discourage you at all, but what you want to do can't be learned in a weekend. Paying a professional, will cost real money. You might be better off working with another racer that has the equipment, and fabrication skills.
yes, that is GREAT information. i think ill employ the help of a welder that has done work for me over the years. i wonder if i can handle the plasma cutting by myself and learn its capabilities . ill probably need a higher rate compressor than i have today.
Mark,
You're Community Collage should have a certified welding program, and they'll have everything you'll need, plus the instructors to teach you. Aluminum welding is an art, and requires a lot of practice to master the technic.
I don't have a clue about the welders at Harbor Freight. My stuff is old, Miller, Lincoln, and Esab. I do have a Cebora Sound Mig double pulse inverter, Italian Mig Welder that is manufactured for Ferrari, to weld aluminum panels on the production line and for panel repairs. 10 years ago it was 26K at the SEMA Show, and I can hook it up to Ferrari's web site and download the Welding Parameter's and procedures. My wife about died when she found out how much I paid for it.
My first choice would be taking a class at the CC, then if that's not practical, buy a used machine. The internet is full of them, or check with the local welding supply houses like Airgas,Praxair, etc. If you're gonna do TIG welding, you'll need the shade made for tig, it's different than Mig, or Arc welding, it's blue not green. Plasma Arcs, or cutters as they're called, are ether conventional and High Definition. Depends what you want the machine to do. You should be looking for a conventional machine. HD, is for minimal dross, larger applications, continuous duty cycle machines in production. Lincoln makes fantastic machines for the home garage.
You'll also need a constant supply of compressed air. Plasma machines use lots of air. Plus there are different backing gases used in welding, and it depends on the base metal. There's going to be a BIG DIFFERENCE between the Aluminum, used by Porsche, and Aston Martin. You'll have that to contend with too. The correct Tungsten is critical, you'll have to learn to read you're Tungsten tips, red or green band, lanthanated or thoriated.
I'm not trying to discourage you at all, but what you want to do can't be learned in a weekend. Paying a professional, will cost real money. You might be better off working with another racer that has the equipment, and fabrication skills.
yes, that is GREAT information. i think ill employ the help of a welder that has done work for me over the years. i wonder if i can handle the plasma cutting by myself and learn its capabilities . ill probably need a higher rate compressor than i have today.
I think so, for what you're doing. Get some scrap, and practice. When you're learning to work the machine, slow and easy is the way. Plus every machine is different. They all have their personality.
12-06-2017, 05:05 PM
