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- Still waiting on Quick Time for pricing. :-(
- Started fabrication of my engine mounts.
- I've been working on the oil pan. It still might be possible to modify the OE pan. I've sent out a second pan to my machine shop to work on that.
- Also working on the intake manifold design. I'm hoping to be able to modify the IE 07K intake with a custom plenum, as shown below. Waiting on IE for dimensions... but I might just have to order one to get what I need. I have the good fortune to know an F1 engine designer through work, and he has offered to give me some guidance on the manifold design. So that's awesome...
- Intake plenum may be made from carbon fiber, fabricated aluminum, or casting. I think carbon fiber will actually be the most cost effective since the tooling is cheaper than casting, and it would be much less labor intensive to make than fabricated aluminum.
So, I’ve been thinking more about the different intake manifold options from a cost standpoint:
- It looks like a modified IE manifold with a custom carbon fiber plenum would likely end up in the neighborhood of $1500 (including $799 paid to IE). I guess tooling for this might only be around $500, so that part is nice.
- I think fabricated sheet metal manifolds would also end up around $1500. No tooling cost, but we would need to make some jigs (which should be pretty cheap).
- A cast aluminum manifold would probably require about $7-10k in tooling. But then the cost per part would be lower. I would guess that if I sold them for around $1000 each, I might recoup the tooling investment after about 20 manifolds.
Can't offer much from an engineering standpoint, but as an owner, longevity would be my main concern. Would there be any longer term issues with carbon fiber degrading or yellowing from heat, fuel vapor, vibration or a combination thereof?
personally, I'd feel slightly better about something that could be relatively easily repaired or modified if needed in the future. Just my 2c of course.
Originally Posted by vt951
So, I’ve been thinking more about the different intake manifold options from a cost standpoint:
- It looks like a modified IE manifold with a custom carbon fiber plenum would likely end up in the neighborhood of $1500 (including $799 paid to IE). I guess tooling for this might only be around $500, so that part is nice.
- I think fabricated sheet metal manifolds would also end up around $1500. No tooling cost, but we would need to make some jigs (which should be pretty cheap).
- A cast aluminum manifold would probably require about $7-10k in tooling. But then the cost per part would be lower. I would guess that if I sold them for around $1000 each, I might recoup the tooling investment after about 20 manifolds.
So, I’ve been thinking more about the different intake manifold options from a cost standpoint:
- It looks like a modified IE manifold with a custom carbon fiber plenum would likely end up in the neighborhood of $1500 (including $799 paid to IE). I guess tooling for this might only be around $500, so that part is nice.
- I think fabricated sheet metal manifolds would also end up around $1500. No tooling cost, but we would need to make some jigs (which should be pretty cheap).
- A cast aluminum manifold would probably require about $7-10k in tooling. But then the cost per part would be lower. I would guess that if I sold them for around $1000 each, I might recoup the tooling investment after about 20 manifolds.
Not sure which way to go... any opinions?
does anybody make a cnc/laser/waterjet intake flange?
fab'd tube and sheetmetal would be definitely easier/cost effective. especially if you make a jig and have someone crank out a batch all at once rather than per-order.
hell, RL user Ak951 is a pretty bad-*** TIG welder in TX who works for a fair price and likes new projects.
CF is "bling" but what does it get you? a few lbs?
cast is best looking but needs a big market to justify the cost.
Good point about carbon potentially degrading due to heat and fluids.
So I'll keep the sheet metal fabricated option on the table. My brother in law is also an excellent fabricator and tig welder, so he could make them. They are just very time consuming to make this way, and therefore end up being pretty expensive.
I would prefer to do the cast aluminum option if the tooling is not outrageous... I'm working on a design that I can send out to get quoted. It may be too much, but I at least want to give it a shot.
I realize your still collecting the dimensions, but would 3D printing be an option? The tech has come a long way recently. From what I understand there are also printers available now capable of printing metal in stainless steel and aluminum.
I realize your still collecting the dimensions, but would 3D printing be an option? The tech has come a long way recently. From what I understand there are also printers available now capable of printing metal in stainless steel and aluminum.
You could definitely have it 3D printed in aluminum by someone like Xometry or Proto Labs, but it's going to be pretty expensive due to the size. Some machining would still be required for the injector bungs, etc.
You could also look into investment casting, since you can cast aluminum parts without tooling using wax molds. We use Invest Cast Inc. at work for prototyping parts since they usually come in at a pretty reasonable price. Just like with metal 3D printing, there is still some finish machining required.
Yeah I might use the 3D printer at work to mock it up for a test fit. Last time I looked 3D printed metal was still really expensive, though. Also I'm not completely sure how the strength compares to cast aluminum. Would it blow up under high boost?
Originally Posted by 87944turbo
I realize your still collecting the dimensions, but would 3D printing be an option? The tech has come a long way recently. From what I understand there are also printers available now capable of printing metal in stainless steel and aluminum.
You could definitely have it 3D printed in aluminum by someone like Xometry or Proto Labs, but it's going to be pretty expensive due to the size. Some machining would still be required for the injector bungs, etc.
You could also look into investment casting, since you can cast aluminum parts without tooling using wax molds. We use Invest Cast Inc. at work for prototyping parts since they usually come in at a pretty reasonable price. Just like with metal 3D printing, there is still some finish machining required.
Love what you guys are doing here. Wish I'd pursued same path.
We had a few partial intake systems printed up for trial fitting. Made me think it could cost a $h!t ton le$$ by doing it that way rather than cnc'ing it.
Love what you guys are doing here. Wish I'd pursued same path.
We had a few partial intake systems printed up for trial fitting. Made me think it could cost a $h!t ton le$$ by doing it that way rather than cnc'ing it.
Wow, that's a beauty. You aussie's spare no expense.
09-16-2018, 01:57 PM
