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Old 07-03-2010, 01:14 AM   #1
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Default A few unusual parts

This isn't a build thread per se but I thought I'd document a few of the parts I've made for my DIY turbo.

Here's #1:



That's a chunk of 303 stainless milled on my benchtop toy mill. In retrospect I should have used aluminum because this took forever.



Three of the ports are -4 AN O-ring bosses and one is M10x1.0.



In, out, pressure and temperature. Also a mounting location for a knock sensor. The pressure transducer is accurate to a fraction of a PSI and has a 2ms response time. The temperature and knock sensors are Audi parts I had lying around.



In situ. The tubing is 316 .035" wall. I struggled mightly to flare it with my POS Summit Racing flare tool:



After wasting a bunch of ($$) tube I bought a proper tool:



That's a Ridgid 377. It works wonderfully.



More to come.

Last edited by kday; 07-03-2010 at 02:18 PM.
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Old 07-03-2010, 01:54 AM   #2
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Diy <3
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Old 07-03-2010, 02:58 AM   #3
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Wow! You did some neat stuff!
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Old 07-03-2010, 12:00 PM   #4
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You're sure the knock sensor will actually do something mounted to a bracket? I always thought their installation directly on the block was pretty critical.
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Old 07-03-2010, 12:36 PM   #5
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Quote:
Originally Posted by SolarYellow510 View Post
You're sure the knock sensor will actually do something mounted to a bracket? I always thought their installation directly on the block was pretty critical.
given that the bracket is steel and not aluminum, and assuming he's mounted it very solidly, the insignificant decrease in sensitivity should be easily 'tuned' out.

Kday, that **** is pro. I'm impressed.
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Old 07-03-2010, 01:14 PM   #6
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You know ,when you are a machininst...everything becomes fair game to be made out of indestrucamanium.Is your mill CNC?I miss being able to Program a mill,there is only so much A CNC lathe is capable of producing,My boss will not allow me to set up the Live tooling on our Mazak...some people just dont get it.
(G)
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Old 07-03-2010, 02:21 PM   #7
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Quote:
Originally Posted by SolarYellow510 View Post
You're sure the knock sensor will actually do something mounted to a bracket? I always thought their installation directly on the block was pretty critical.
It's still a rigid mount. There's no free M8 boss on the block anyway. FM does something similar with their knock sensor mount.
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Old 07-03-2010, 02:23 PM   #8
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Quote:
Originally Posted by Reverend Greg View Post
You know ,when you are a machininst...everything becomes fair game to be made out of indestrucamanium.Is your mill CNC?I miss being able to Program a mill,there is only so much A CNC lathe is capable of producing,My boss will not allow me to set up the Live tooling on our Mazak...some people just dont get it.
(G)
It's a manual Harbor Freight mini-mill. Lots of people have made DIY CNC machines out of these though, using e.g. EMC (Linux-based CNC), and if I ever run out of projects that sounds like a fun one to tackle.
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Old 07-03-2010, 03:57 PM   #9
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I got our FSAE team to get that same Rigid flair tool, it rocks my world.
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Old 07-03-2010, 04:12 PM   #10
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Kday, I have the HF micromill, and a 7x14 lathe. Knowing the capabilities of those little machines, I'd say that was pretty good work. I know my machines don't like to cut stainless, or even mild steel.
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Old 07-03-2010, 04:28 PM   #11
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Quote:
Originally Posted by rleete View Post
Kday, I have the HF micromill, and a 7x14 lathe. Knowing the capabilities of those little machines, I'd say that was pretty good work. I know my machines don't like to cut stainless, or even mild steel.
Yeah, thanks. I think with enough time I could have gotten better surface finish everywhere, but it was such slow going I didn't have the patience for aesthetics.
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Old 07-03-2010, 04:33 PM   #12
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You get me HOT!
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Old 07-04-2010, 08:18 PM   #13
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Very nice. Do you happen to know what size that nut is that holds the oil filter housing on the block? (edit) Derp it's 29mm.

Nice work with the flares, I have a bad history with ruining those things.

Last edited by saedrin; 07-04-2010 at 08:44 PM.
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Old 07-08-2010, 12:59 AM   #14
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Originally I was going to make a totally new water pump inlet, with a -16 or -20 AN inlet from the radiator, a -10 from the heater core, and -6 ports for both the oil cooler/warmer and the turbo. I'm getting impatient to get the car on the road though so I took a shorter route:



There is just enough meat on the hose barb boss to tap for 1/4 NPT. I wanted to use a -6 ORB instead but I wasn't sure I'd have enough material to make the O-ring seat. I will use a NPT to male -6 and then a -6 tee to both the oil cooler and the turbo hard lines.

Incidentally these spring loaded tap guides are awesome:



Sorry for the crappy pictures, I forgot how the insanely bright LED work light messes with the camera.
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Old 07-08-2010, 02:41 AM   #15
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Nice, the little block you made is legit as hell. I want to diy like this!
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Old 07-08-2010, 12:15 PM   #16
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I done that with my turbo build, spun the mixing mani around:

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Old 07-08-2010, 12:43 PM   #17
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Ok, that last one was insufficiently unusual. I'll try harder next time.
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Old 07-08-2010, 12:45 PM   #18
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^not even trying to one-up. Just wanted to show how it looks in it's completed state.
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Old 07-08-2010, 01:06 PM   #19
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Heh, no worries, I was just kidding.

I'm going to mount the manifold in its normal orientation, at least until my AVO manifold cracks in half and I need to replace it.
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Old 07-08-2010, 05:50 PM   #20
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Very nice stuff! I know how difficult it can be to machine stuff with a chinese tabletop mill. My dad has a Smithy which I'm sure is more rigid than the HF crap and it still chatters like crazy. Nice job on the hardlines too

Quote:
Originally Posted by Reverend Greg View Post
...there is only so much A CNC lathe is capable of producing,My boss will not allow me to set up the Live tooling on our Mazak...some people just dont get it.
(G)
Tell your boss to get with it! We make these at work in one operation (bar goes in one side, finished part comes out, minus honing & polishing & heattreat) on a live tooling lathe:

Turning Is Optional


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