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Min
Joined: 04 Nov 2002
Posts: 2368
Location: Vernon, British Columbia, Canada
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 Posted: Sun Sep 28, 2008 6:23 am Post subject: What to build what to build *ponder* |
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well, I just bought myself a milling machine (smallish one) I have a lathe, welder/etc, and I'm wondering to myself what I should build. If you guys had these tools, and the skills/knowledge to use them, what would you build? I also recently got access to a 12 foot by 6 foot plasma CNC table also.
Min
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Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting. |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Sun Sep 28, 2008 6:52 am Post subject: |
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Phenolic spacer
Injector inserts
Rear axle pulley for alt & other such accessories
Trigger wheel
Fuel rail
Lightweight pulleys
Adapter brackets for power steering rack
All kinds of misc bracketry
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erstwhile owner of just about every 924 variant ever made |
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Min
Joined: 04 Nov 2002
Posts: 2368
Location: Vernon, British Columbia, Canada
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| Posted: Sun Sep 28, 2008 9:32 am Post subject: |
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| ideola wrote: | | Phenolic spacer |
Ok
| ideola wrote: | | Injector inserts |
I don't have proper threading control on my lathe so I won't be able to make these just yet, I'm not happy with the finish that a die gives for the threads.
| ideola wrote: | | Rear axle pulley for alt & other such accessories |
where were you going to mount the pulley again?
| ideola wrote: | | Trigger wheel |
Easy peasy
Just ordered the correct tooling to do a proper job of that.
| ideola wrote: | | Lightweight pulleys |
I've looked into this, I need a slightly larger lathe to be able to properly machine the crank pulley. I can machine alternator and waterpump pulleys though (and have in the past)
| ideola wrote: | | Adapter brackets for power steering rack |
ooooo, your installing power steering on the UWB ?
| ideola wrote: | | All kinds of misc bracketry |
Ya I'm gunna redo the alternator relocation bracket I made so its a bit prettier, which is part of the VR sensor bracket. Gunna powdercoat them this time too so they arn't quite so ugly.
Min
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Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting. |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Sun Sep 28, 2008 10:40 am Post subject: |
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| Min wrote: | | ideola wrote: | | Rear axle pulley for alt & other such accessories |
where were you going to mount the pulley again? |
In a similar location as on Frank's D-Prod car:
I've found one pulley that will work, from an early Ford 351 Windsor, I think. But it is HEAVY. The intent is to hog out the middle of the pulley to a diameter of just about 3.5" or so, which will allow the CV boot to slip through it, and still leave enough surface area to drill out the bolt pattern to match the CV joint. The pulley will be mounted to the inside CV joint using the six bolts that attach the CV joint to the stub axle. Of course, longer bolts will need to be sourced. This approach prevents any modification to the geometry or positioning of the axles shafts.
I tried unsuccessfully to get more information on how the alt was setup on Frank's car. In this picture, it appears that he's just using a flat or ribbed belt running directly on the CV joint itself, but I am concerned about it slipping off, so I want a pulley instead. At the same time, I don't want to do any modification to the axle shaft (such as machining it or welding onto it, etc.), because I want to keep things as stock as possible for maintenance.
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Sun Sep 28, 2008 10:42 am Post subject: |
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The other thing I just thought of that would be really cool would be to fabricate some delrin bushings to replace the rubber transmission mounts. In my case, I'd like them for the snail shell, but Audi style would be useful as well.
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Sun Sep 28, 2008 11:02 am Post subject: |
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| Min wrote: | | ideola wrote: | | Adapter brackets for power steering rack |
ooooo, your installing power steering on the UWB ? |
Yep, Chris Marsh is making up adapter brackets for me that will allow me to bolt the 924S power steering rack directly onto a stock early cross member. Hope to have them in the next week or so, and I think he's doing a small run, like maybe a dozen or so.
I am planning to put a 924S power steering rack on both the UWB as well as the 941. The 8" wheels combined with 13" Momo Corse steering wheel give me quite a workout...looks cool, but steering is a bit too heavy for extended driving, even at speed.
I'm 95% certain this approach will be a pretty-much bolt-on solution, but I won't know for sure until I get the brackets in my hands and can do some test fitment on the 941. My biggest concern right now is whether the input shaft housing from the rack to the steering shaft will clear the A/C compressor. The input shaft housing is taller than on the manual rack...eyeballing it appears to be enough room, but you never no until you try fitting it. Obviously not a huge deal on the UWB because it won't have A/C, but for broad applicability, it would be nice to not have to sacrifice the A/C compressor.
To complete the setup, I will be removing the stock 931 expansion reservoir, and replacing it with a 944 unit. This will free up space on the driver side frame rail for brackets that will accommodate the power steering pump and an electric motor. This location will probably necessitate modifications to the lines from the pump to the rack, but a local stainless/hydraulic hose shop should have no trouble with that.
Exact speed of the electric motor will be determined thru testing. Initial phase, the motor will run at continuous RPM, minimum of 1200 which is roughly analogous to idle speed, the speed at which all power steering racks are designed to deliver optimum assist (i.e. minimum threshold during slow speed maneuvers). Later on, I may later play around with manual or automated variable control, but for initial phase, I'm planning to keep it simple. I don't need a lot of assist, just enough to take some of the heaviness out of the current manual setup.
I've been intending to upgrade my alt anyway, so as part of this winter project, I will probably also convert over to a 140 AMP Delco-Remy alternator (EDIT: on the 941, the UWB will probably get a 200 AMP unit) just to be sure I have enough capacity to accommodate the electric motor.
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Min
Joined: 04 Nov 2002
Posts: 2368
Location: Vernon, British Columbia, Canada
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| Posted: Sun Sep 28, 2008 5:17 pm Post subject: |
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Ah, might be able to machine a pulley to go on the cv would have to do a bit of measuring though, the main limitation would be the outter edge, my lathe is only designed to spin a piece 6 inchs round, and at that size I can't machine the outer edge, only the face. So if I can make it small enough that I can machine the outer edge I could make a pulley to slip over the cv axle. I may be able to make some tools that allow me to extend the range of my lathe slide. Hrm, hrm, hrm.
I just finished milling some m18 1.5 o2 sensor plugs flat so I can use them to plug some holes in a toyota's exhaust manifold. I took some pictures of it in action yesterday, I just gotta get them from my friends cell phone onto my computer so I can post them.
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Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting. |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Sun Sep 28, 2008 9:42 pm Post subject: |
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For the axle-drive pulley, 6" is ideal as it matches pretty close to the crank pulley, BUT, it's not a huge deal...if the axle-drive pulley is 5", then you just need to play around with the pulley on the alt along with belt length until you achieve the right ratio to get the RPM you want at the alt. There's a few online calculators to help with this. If you could machine a 5" pulley out of lightweight alu, I'd ditch the heavy used pulley I have right now. I'm still planning to go to a local salvage yard or two and see if they have any bins full of pulleys just to see if I can find something lighter weight than what I have.
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pocketscience
Joined: 23 Apr 2006
Posts: 1650
Location: Sydney, Australia... mate!
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bass gt
Joined: 02 Dec 2004
Posts: 971
Location: Johannesburg for now!!
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| Posted: Sun Sep 28, 2008 10:40 pm Post subject: |
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Gavin
You can use snailshell gearbox oil drain plugs, which cost a couple of quid each!! I have and they work a treat
Steve
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Lizard
Joined: 03 Nov 2002
Posts: 9364
Location: Abbotsford BC. Canada
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| Posted: Mon Sep 29, 2008 2:34 am Post subject: |
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Dan, He has just disassembled the CV and put the outter shell into a lathe and had 5 or 6 groves cut into the CV to be able to run the altenator and that belt will not slip off.
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3 928s, |
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ideola
Joined: 01 Oct 2004
Posts: 15550
Location: Spring Lake MI
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| Posted: Mon Sep 29, 2008 3:17 am Post subject: |
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| Lizard wrote: | | Dan, He has just disassembled the CV and put the outter shell into a lathe and had 5 or 6 groves cut into the CV to be able to run the altenator and that belt will not slip off. |
Yeah, that's what I want to avoid. Plus, with a pulley, I can drive multiple items. Bwahahahahah [evil laugh].
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Mon Sep 29, 2008 5:27 am Post subject: |
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Adapters to bolt up Boxter Brembos to our cars would be outstanding.
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- WeiBe (1987 924S 2.5t) - 931 S3
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Min
Joined: 04 Nov 2002
Posts: 2368
Location: Vernon, British Columbia, Canada
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| Posted: Mon Sep 29, 2008 10:09 am Post subject: |
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| Rasta Monsta wrote: | | Adapters to bolt up Boxter Brembos to our cars would be outstanding. |
Wouldn't there be clearance issues on the rims? How large are boxster brembo's? do you have a set?
Min
_________________
Custom means it didn't come from a box.
1980 n/a with EDIS and Megasquirt II Injection. 7 different colors and counting. |
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Rasta Monsta
Joined: 12 Jul 2006
Posts: 11733
Location: PacNW
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| Posted: Mon Sep 29, 2008 10:27 am Post subject: |
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They fit under 16s. I saw some adapters on ebay.uk (pointed out by someone here) but haven't been able to find them again.
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Toofah King Bad
- WeiBe (1987 924S 2.5t) - 931 S3
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