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Old 07-28-2015, 05:11 PM   #2441
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<p>Probably. Might have to trade you a new vent window. Mine cracked.</p><p>They are m8x1.25.</p>
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Old 07-28-2015, 05:15 PM   #2442
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Where'd it split at, around the actual vent?

I'm thinking I need to come up with a router pattern to cut them from lexan. I have no idea how to hold the template to the lexan sheet, other than sticky tape, maybe huge c-clamps? Mine has a few little hairline cracks around the vent, but I thought I'd made the other's vents slightly larger so they hopefully wouldn't do that...

My bad man!

M81.25 is what I need, don't think I can fit much bigger on this iron manifold.
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Old 07-28-2015, 05:17 PM   #2443
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<p>Straight up from the vent. Buddies cracked from the edge on installation. Its not horrible, and its still usable. But I'll definitely trade you the bolts for some lexan ones.</p><p>Someone needs a CNC mill. (hi_im_sean?)</p>
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Old 07-28-2015, 05:25 PM   #2444
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I have a mill, but I'm stuck to tormach 1100 and not enough Y travel to make a window...

I think if I had a set of small deep throat c-clamps and a pre-cut piece of lexan about the right size might work, I'd just need to move the clamps as I go around the profile.

Let me see what I can do
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Old 07-28-2015, 05:47 PM   #2445
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My machines are all manual, my Y is only 7-7/8" anyway. (i do have x and y stepper controllers and an old serial capable tower sitting around for that exact purpose, not happening anytime soon though)

For the router table, just bolt through where the vent holes is and clamp the template to the table with the lexan in between, line the perimeter with 1/4" single sided foam tape to keep the pressure around the perimeter of the template. then use a 2nd template for the vent hole centered on the clamping hole made earlier.
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Old 07-28-2015, 05:48 PM   #2446
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<p>
Quote:
Originally Posted by hi_im_sean View Post
then use a 2nd template for the vent hole centered on the clamping hole made earlier.
</p><p>Or a holesaw?</p>
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Old 07-28-2015, 05:50 PM   #2447
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<p></p><p>Or a holesaw?</p>
Its not the cleanest way, and still needs to be clamped well to avoid spitting, but yea, that could work too.
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Old 07-28-2015, 05:51 PM   #2448
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<p>Cut template from plywood, clamp plywood, cut around plywood?</p>
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Old 07-28-2015, 05:54 PM   #2449
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<p>Cut template from plywood, clamp plywood, cut around plywood?</p>

Correct. Plywood template needs to be cut smaller than the actual piece by the difference between the router cutter radius and the guide bearing radius.
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Old 07-28-2015, 05:56 PM   #2450
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Plan is to use a handheld router using a plywood template, I don't have a router table either unfortunately.

My thought is cut a window at size in plywood, then cut one slightly under to the router bearing size. Move the c-lamps around the perimeter as I hit them with the router. The wood template will let me route the inner vent hole as well, so I don't have to buy a hole saw.

Or I could just make the vent hole and somehow clamp through that, maybe?

I think I can laser cut 1/4" MDF, and that ought to work as a template rather well.
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Old 07-28-2015, 06:00 PM   #2451
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Or I could just make the vent hole and somehow clamp through that, maybe?

.
Thats what I was saying, for use with a handheld. I might have confused you when I said "clamp it to the table". I just meant clamp through whatever work surface you are using, wooden bench, plywood on saw horses etc. with a bolt and a wingnut or something.



Yet another idea if you have a decent sized drill press, or A frame type press is to just clamp down on the template with the spindle or press ram and router around it.
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Old 07-28-2015, 06:04 PM   #2452
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Heh, why didn't I think of that. It'd be easy to route the hole, then my pattern can be keyd to the table with dowel pins and a wingnut as a clamp, lexan in the middle. I doubt I could spin the lexan under the pattern, not like I'll need to power through it too hard.

I'm gonna try and laser cut some MDF tonight, otherwise I'll probably have to trace and hand cut my pattern off one of the acrylic windows. Besides the cracking you are alright with the size of the things, right Aiden?
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Old 07-28-2015, 06:17 PM   #2453
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On your "base"(table, bench whatever) glue or screw a thin round (about 1/2" thick i suppose) of the material of your choice that is the same diameter as your vent hole. We'll call this the "vent dowel". Cut the vent hole full size in your pattern where it would actually go.

1. Make lexan blanks (precut rectangles to the size you need)
2. Install vent hole in lexan ( hole saw, router, whatever)
3. Slip the lexan onto the vent dowel on your table.
4. Slip the pattern over the vent dowel. (if your not getting it yet, the vent hole and dowel locate and clamp everything all in one)
5. Clamp.
6. Cut.
7. Send one to Sean for his awesome ideas.
8. Profit, retire early, generally win at life.
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Old 07-28-2015, 06:58 PM   #2454
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Haha, fair enough! I'd be more than happy to make you a set, especially since I foresee being able to stack pre-cut lexan sheets onto my alignment dowel. If I'm not mistaken I should be able to churn these things out pretty damn quick, probably even faster than the laser.

I'm gonna need to order lexan though, because home depot only has thin crap.
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Old 07-28-2015, 07:00 PM   #2455
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<p>Yeah, hole placement is solid. Size seems to work fine. I know you had some issues with sizing around the vents. Mine turned out like barely too tight. But I would much prefer too tight over too loose.</p>
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Old 07-28-2015, 07:30 PM   #2456
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The depot is a ripoff for fabricating materials compared to what you can find at a materials supplier or even the internet with shipping. I only go for emergencies, or if im being lazy. The router bit length will be your limiting factor obviously, you should be able to do 3 or 4 at a time.

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But I would much prefer too tight over too loose.
Who doesnt?
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Old 07-28-2015, 10:22 PM   #2457
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<p>Glad that was caught.</p>
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Old 07-28-2015, 10:25 PM   #2458
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???
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Old 07-28-2015, 10:27 PM   #2459
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Loose and tight
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Old 07-28-2015, 10:47 PM   #2460
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Default Community build thread...Aidan occasionally does the things

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Loose and tight
You need to fly to Atlanta for the Miataturbo.net get together in 3 weeks.
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