sonus
Europe
Posts: 1,391
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I need to make eight cones that is 175mm long that has an internal diameter of 40mm one end and 30mm the other end. They are going to be used as i take runners for a cross ram manifold (carbs on onside feeds the opposite bank on a V8).
The wall thickness would be 5mm to mate up to some Ø50x5mm bends on each cone end.
My question is as follows; Would you start with a pipe ø50x5mm split it down the length by removing a pie shaped bit, heat it, shape it and weld it to get the cone shape? Or start with a Ø50x10mm tube and machine it so that one end is Ø50x5 and the other is Ø40x5mm to make the cone? How hard would it be to machine the inside of a Ø30 tube?
Hope this makes sense?
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Current
1968 TVR VIXEN S1 V8 Prototype
2004 TVR T350C
2017 BMW 340i
Previous
BMW 325d E91LCI - sold
Alfa Romeo GTV - sold
Citroen AX GT - at the breakers
Ford Puma 1.7 - sold
Volvo V50 2.0d - sold
MGB GT - wrecked by fire
MG ZT 1.8T - sold
VW E-golf Electric - sold
Mini Countryman 1.6D -sold
Land Rover Discovery TD5 - sold
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93fxdl
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fad
Posted a lot
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Splitting a pipe with a pie cut doesn't work as well as it does in your head unless you do some very careful maths and even more careful cutting, and even then you have to then machine or cut either end to make it flat again (you end up with curved V-shaped ends). It is doable but a royal pain in the ass to get it to line up - loads easier with jigs mind you (I used to help out a mate who owned a one-man sheet metal working place, he had to make a cone that fitted offset on a large cylinder for an industrial coffee grinder, you wouldn't believe the agro in making it fit up!).
A lathe would surely be the way to get the best results here?
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A decent engineering shop should be able to swage 40mm pipe down to 30mm for you.
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I'm assuming alluminium?
If so, I don't like the idea of trying to cut and re bend pipe. I also don't like the idea of trying to machine it.
Thats purely due to my abilities though.
Out of the two, id try modifying pipe.
But, if I needed those parts, I think id see it as a good oppertunity to bodge together a forge and try casting alluminium.
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fad
Posted a lot
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Casting is an interesting idea. I know someone who made a forge from fire clay, an old stainless sink, a busted hair dryer and a load of charcoal. All in cost him about £15 to make.
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sonus
Europe
Posts: 1,391
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Thanks all!
How about "spinning" a smaller diameter pipe to make it larger one end?
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Current
1968 TVR VIXEN S1 V8 Prototype
2004 TVR T350C
2017 BMW 340i
Previous
BMW 325d E91LCI - sold
Alfa Romeo GTV - sold
Citroen AX GT - at the breakers
Ford Puma 1.7 - sold
Volvo V50 2.0d - sold
MGB GT - wrecked by fire
MG ZT 1.8T - sold
VW E-golf Electric - sold
Mini Countryman 1.6D -sold
Land Rover Discovery TD5 - sold
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sonus
Europe
Posts: 1,391
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Here is the idea for the manifold   |
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Current
1968 TVR VIXEN S1 V8 Prototype
2004 TVR T350C
2017 BMW 340i
Previous
BMW 325d E91LCI - sold
Alfa Romeo GTV - sold
Citroen AX GT - at the breakers
Ford Puma 1.7 - sold
Volvo V50 2.0d - sold
MGB GT - wrecked by fire
MG ZT 1.8T - sold
VW E-golf Electric - sold
Mini Countryman 1.6D -sold
Land Rover Discovery TD5 - sold
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You could reduce the diameter anywhere along the straight part of the plenum with no detrimental effect instead of having a long conical reducer.
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pressing a cone bar would do these
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You will not make them out of modified tube without a serious amount of ball-ache and cost , anyone you suggest that to would suggest machined something as a much easier option , you simply will not be able to easily for 5mm thick aluminium tube of such a small diameter .
And as above , i really don't think the long tapered tube is necessary for performance.
Why not just get some aluminium adaptors made up , say 15-20mm long , small diameter one end , large the other , small end fits inside to weld , bigger end slips over . Easy enough for anyone or any machine shop to do .
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sonus
Europe
Posts: 1,391
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Last Edit: Mar 4, 2017 5:13:26 GMT by sonus
Current
1968 TVR VIXEN S1 V8 Prototype
2004 TVR T350C
2017 BMW 340i
Previous
BMW 325d E91LCI - sold
Alfa Romeo GTV - sold
Citroen AX GT - at the breakers
Ford Puma 1.7 - sold
Volvo V50 2.0d - sold
MGB GT - wrecked by fire
MG ZT 1.8T - sold
VW E-golf Electric - sold
Mini Countryman 1.6D -sold
Land Rover Discovery TD5 - sold
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If all 8 tubes are identical i would look at finding someone to cast them for you. There are a lot of firms out there that offer low production run castings. If you can get the drawing done in a CAD file you can e-mail it to them and they can provide a quote for it fully cast and even the surfaces machined.
It would enable you to have exactly what is drawn above, rather than spend hours and hours trying to turn straight tube into such a smooth radiused/cone shape. I'm sure it COULD be done but it is neither going to be easy or quick to get one made never mind 8 of them.
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No it will split , it to thick a diameter to do that , plus you will need to visit a machine shop for them to make a cone and a former up .
The easiest way of making your manifold would have been to get the one off your car and adapt it - machine the top off and weld a adaptor on for what carbs you want .
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will need to use 'commercial' or 'pure' ally, cant remember the proper name for it atm. you will need plenty of grease on the former tube as well
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v8ian
Posted a lot
Posts: 3,819
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Use 30mm pipe, and find a good exhaust place that has a hydraulic swager, they would be able to swage the pipe up to your required size then use a die grinder and a burr to blend the internals
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Last Edit: Mar 4, 2017 10:31:04 GMT by v8ian
Atmo V8 Power . No slicks , No gas + No bits missing . Doing it in style.
Austin A35van, very different------- but still doing it in style, going to be a funmoble
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