3d printed intake for N/A NA miatas - Page 3 - Miata Turbo Forum - Boost cars, acquire cats.

Welcome to Miataturbo.net   Members
 


Engine Performance This section is for discussion on all engine building related questions.
Sponsored by:
Sponsored by:

Reply
 
 
 
LinkBack Thread Tools Search this Thread
Old 11-26-2013, 02:27 PM   #41
Junior Member
iTrader: (1)
 
Join Date: Feb 2011
Location: Richmond, VA
Posts: 320
Total Cats: 20
Default

A lot of FSAE / FSG teams Rapid prototype their manifolds, lots of information on their forums. I was nearby for an early version exploding at a competition. The resulting talk was of pressure relief valves but in the end, most teams just went stronger. Pre throttle body, its still an issue for them.

PA66 with 30%GF via SLS has proven to be the most durable variation though it typically costs north of $1k to make. You would only use this method to create a mold and then fabricate one using other means unless you are wealthy or sponsored.

PA66 = nylon 66. 30% GF means 30% embedded with glass fibers for strength. External rib and strength elements are important just as though you were doing a PA66 molded design. Material choice is important as many consumer plastics will lose significant strength or melt under the hood.

Should be easy to model airflow through your design.
vtjballeng is offline   Reply With Quote
Old 11-26-2013, 03:13 PM   #42
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

I don't know/use any cad software and can't do flow modeling myself. However, if someone is interested I can get them the model in any format that 3dsmax outputs.
asmasm is offline   Reply With Quote
Old 11-26-2013, 03:15 PM   #43
Elite Member
iTrader: (1)
 
Leafy's Avatar
 
Join Date: Jun 2012
Location: NH
Posts: 9,037
Total Cats: 99
Default

Quote:
Originally Posted by asmasm View Post
I don't know/use any cad software and can't do flow modeling myself. However, if someone is interested I can get them the model in any format that 3dsmax outputs.
.stp/.step or .iges would cover most people's modeling software.
Leafy is offline   Reply With Quote
Old 11-26-2013, 10:45 PM   #44
Senior Member
iTrader: (3)
 
Join Date: Jul 2011
Location: STL
Posts: 528
Total Cats: 24
Default

midpack is offline   Reply With Quote
Old 11-26-2013, 11:12 PM   #45
Junior Member
 
Join Date: Mar 2012
Posts: 320
Total Cats: 23
Default

Your avatar with that video preview is hilarious.
M.Adamovits is offline   Reply With Quote
Old 11-27-2013, 02:37 PM   #46
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

I made my first attempt to fit an AEM dryflow filter. I have the narrowest 70mm filter and it doesn't fit. For anyone else looking to do this, a 5.5" filter is too big. Next up is a k&n RC-9310 (4.75" base).
asmasm is offline   Reply With Quote
Old 12-01-2013, 01:11 PM   #47
Supporting Vendor
iTrader: (1)
 
Join Date: May 2010
Location: San Diego
Posts: 486
Total Cats: 37
Default

Quote:
Originally Posted by asmasm View Post
I made my first attempt to fit an AEM dryflow filter. I have the narrowest 70mm filter and it doesn't fit. For anyone else looking to do this, a 5.5" filter is too big. Next up is a k&n RC-9310 (4.75" base).
Check the K&N RC-9800, I used it for my cold side intake as it was the only thing that would fit. I think the dimensions are close to what you want.



RC-9800 - K&N Universal Air Filters, Universal Chrome Filter direct from K&N
Attached Thumbnails
3d printed intake for N/A NA miatas-5tixq0kl.jpg  
Lincoln Logs is online now   Reply With Quote
Old 12-01-2013, 02:03 PM   #48
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

I got my rc-9310 and it is close to fitting. I am adjusting the design around this specific filter.


The flange ID of the filter you posted was too small.
asmasm is offline   Reply With Quote
Old 12-06-2013, 09:24 AM   #49
Newb
 
Join Date: Aug 2009
Posts: 21
Total Cats: 0
Default

Quality of SLA's can certainly vary. I can tell you that I use SLA's to prototype valves of all types, and mostly test them with compressed air. I've not had trouble with them leaking or breaking (we aren't after world class leak standards in this application).

Only trouble I've had over the years is surface finish and brittleness with high temp resins.

Just to toss my 2 cents in, SLA materials have come a long way, but the resins I'm familiar with shouldn't be trusted long term under the hood. Great for prototyping / proof of concept work. Great for then building some tooling from. At a minimum, I would take the SLA and use it as your base substrate for applying fiberglass / kevlar / carbon overlay. You'll want to increase the strength / toughness somehow.
thefoos is offline   Reply With Quote
Old 02-27-2014, 06:10 PM   #50
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

I finally got one of the prototypes running on my car (this one looks like dog **** on the outside but is nice and smooth inside). I am still on stock engine management so I am running the maf and had to source a few things to get it working. First test drive and it feels noticeably better than stock. I didn't feel any bogging or weakness in the mid range either. Hopefully dyno time will confirm my perception. I'll also get some IATs logged on the street to compare with other aftermarket intakes. My thought with this design is that it will work very well for auto-x where you sit still in grid for 10 minutes at a time with a hot engine.


I am getting a print of what I hope is the last design revision some time next week and if the fit is improved I will get a new model file onto thingiverse along with a full list of parts needed for people to get it running.
asmasm is offline   Reply With Quote
Old 02-27-2014, 06:17 PM   #51
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

Oh also, there should be a commercially available composite version coming. I would rather let that company announce parts availability when they are ready but if the final cost is reasonable it will be a much stronger/better option.

Last edited by asmasm; 02-27-2014 at 06:41 PM.
asmasm is offline   Reply With Quote
Old 03-02-2014, 10:30 AM   #52
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

I ran an auto-x which was 6 runs with some time on the rev limiter and an hour and a half highway/back roads drive with no issues so far.

Here is a breakdown of parts needed:




You can re-install the cooling shroud, and I plan to put it back on soon. Also, I removed the stock hood prop but if you want to keep it on the car you can give it a slight bend to get it out of the way. It still works with the bend on it but the intake prevents you from using it.
Attached Thumbnails
3d printed intake for N/A NA miatas-ur2zw64.jpg   3d printed intake for N/A NA miatas-brsiysl.jpg  
asmasm is offline   Reply With Quote
Old 03-05-2014, 09:23 PM   #53
Junior Member
iTrader: (2)
 
Join Date: Apr 2013
Location: Bryan, TX
Posts: 149
Total Cats: 7
Default

I can haz one?
Code Monkey is offline   Reply With Quote
Old 03-05-2014, 09:47 PM   #54
I'm Miserable!
iTrader: (1)
 
Join Date: Aug 2011
Location: SWFloriduh
Posts: 114
Total Cats: 9
Default


Got a part number on that black elbow and the chrome piece ?
Boris is offline   Reply With Quote
Old 03-06-2014, 12:26 AM   #55
Supporting Vendor
iTrader: (1)
 
Join Date: May 2010
Location: San Diego
Posts: 486
Total Cats: 37
Default

Quote:
Originally Posted by Boris View Post
Got a part number on that black elbow and the chrome piece ?
2.5" black 90* elbow.

Silicone 90

For the piping, buy one of the Mandrel Bent Aluminum 45/180 Bend, 2.5" and cut to size.

Stainless Steel Piping
Lincoln Logs is online now   Reply With Quote
Old 03-12-2014, 07:25 PM   #56
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

shiny:




That design is totally done but I had an idea for how to make a superior duct that would be cheaper to get printed so now I am starting over. The new version is similar but doesn't incorporate the 45 degree bend as it nears the engine and I added more clearance to allow it to be rotated to face the throttle body. On cars with stock style radiators the implementation will be about the same except a large silicone 45 degree elbow is used instead of a straight coupler. The big advantage will be with for people who have aluminum flat topped radiators. With the duct rotated to face the throttle body and a 45 degree coupler on the TB the intake ends up being almost exactly 22" long:
Attached Thumbnails
3d printed intake for N/A NA miatas-57lgsge.jpg   3d printed intake for N/A NA miatas-dphmonn.jpg  
asmasm is offline   Reply With Quote
Old 03-13-2014, 12:24 PM   #57
Senior Member
 
Join Date: Sep 2013
Posts: 903
Total Cats: 59
Default

All of the dyno shops locally are a pain in the *** to deal with, so we're going going to do a foam pour on my car (TSE rad) and do some A/B testing as soon as I can get an appointment.

ETA: probably a week before TSE puts up their turbo kit :P
Dunning Kruger Affect is offline   Reply With Quote
Old 03-13-2014, 02:08 PM   #58
Senior Member
 
Join Date: Mar 2006
Location: Schwarzenberg, Germany
Posts: 1,495
Total Cats: 81
Default

I really like that, probs given...

You should consider a heat shield on the back of the air filter to the watercooler...?!
Zaphod is offline   Reply With Quote
Old 03-13-2014, 02:15 PM   #59
Senior Member
Thread Starter
iTrader: (1)
 
Join Date: Jul 2012
Location: durham NC
Posts: 758
Total Cats: 105
Default

Yeah, I have been planning to do a bent aluminum heat shield with a silhouette that matches the filter. Also, its kind of hard to tell from the pictures but there is about 4" between the edge of the filter and the radiator.

The 3d printer I am currently working with can get these out to people for about ~$130 shipped (CONUS). [email protected] The newer design should end up at $100 shipped. This is significantly more expensive than the other printers I have worked with but the part quality and strength is better. He is using a fine layer height which means these take something like 24 hours of time on his printer to produce. He also does an acetone vapor bath which smooths things out really well:



The design is also on thingiverse, I updated the files today. I have paid as little as $40 to have one of the early prototypes done so you can try and find a cheaper printer. However, that was with a larger layer height and less fill density. My break tests have showed those parts being significantly weaker. Also, having worked with 4 different printers on this so far, two of them started prints but were unable to make successful parts.

NA miata intake duct by AlecMoody - Thingiverse

I have messed around with the shapeways white strong and flexible material and it is extremely strong but I am concerned it won't hold up to the heat well enough. At some point I am going to cram a test piece into the radiator area and see what happens. Shapeways will also cost a fortune (something like $370) but it will be done quickly and in one piece.

Last edited by asmasm; 03-13-2014 at 02:31 PM.
asmasm is offline   Reply With Quote
Old 03-13-2014, 02:40 PM   #60
Boost Czar
iTrader: (61)
 
Braineack's Avatar
 
Join Date: May 2005
Location: Chantilly, VA
Posts: 72,463
Total Cats: 1,698
Default

you know this is miataturbo.net, right?

not to be confused with miataslowcar.net.
Braineack is offline   Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
Bunch of NB stuff - mspnp2, begi intake mani, injectors mikeflys1 Miata parts for sale/trade 12 05-01-2016 09:51 AM
3rd Time's a Charm...hopefully. zephyrusaurai Meet and Greet 2 09-28-2015 10:59 PM
Another Alternator thread ihiryu General Miata Chat 9 09-28-2015 10:22 AM
starting issue Johnny Tater Engine Performance 3 09-23-2015 06:10 PM
1991 Turbo Miata partout tottestad Miata parts for sale/trade 18 09-14-2015 07:52 PM


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -4. The time now is 12:54 PM.