Inlet Manifold

[Martin Kemp]

It's working for me

Martin

[F1300Tony]

Nice job, Dave. Starting with the CAD, that is a lot of work. According to 750F myth it should have been cast from empty beer cans.

[Dave Robson]

Thanks Tony. Yes the CAD design took me ages with lots of re-work. It was a steep learning curve. Whether it results in a better product is to be seen. In some ways it was an ideal project whilst I was locked in. The furnace design and construction was another development project that has eventually works and seems to be reliable. The source of aluminium is from broken up A Series gearbox castings. (I don't drink enough beer!)
Dave

CAD screenshot of manifold pattern

Manifold Body.jpg (72.84 KiB) Viewed 86 times

[Martin Kemp]

Did you shell the inside or are the airways a separate model subtracted from the outside,

Martin

[Dave Robson]

Martin,
I developed the 'airways' and then shelled externally to create the mould for the core. This was split horizontally. See picture.

The pattern for the manifold body came from the same 'airway' and was also shelled externally, flanges added, core imprints added, made solid and then split horizontally.

This is why my beard is grey !!

Dave

Core mould.jpg (30.76 KiB) Viewed 74 times

[Martin Kemp]

That's the way I would do it too.
It would interesting to rapid prototype a manifold with SLS Polyamide. It might be difficult to get it to support the mass of a Weber but a Tillotsen would be no problem. The cost for such a large item might rather higher than for a steel fabrication though,

Martin

[F1300Tony]

For 2013 we had a very long manifold made in nylon 6 with an internal coating to make it resistant to fuel. It didn't work due to fuel pooling, not because of the material. When the throttle was closed the pool evaporated and wet the plugs, and then it took out the head gasket. The weight of the 45DCOE was taken by a strut from the engine.