Monday, October 3, 2011

4 into 1

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I now have all 4 individual throttles and shafts spaced appropriately and operating smoothly. I was fortunate that the original horizontal mounting brackets on the throttles ended up in a vertical orientation. Using the previously drilled mounting holes that were in the brackets. All that was required was 2 x 305mm pieces of threaded rod and 6 precisely measured aluminum spacers.
The 4 throttle bodies are still able to be separated mechanically. I was originally going to have them machined and welded in sets of two. However, I like the fact that they are individual and can be replaced or worked on without any major machine work requirements.
Another bonus is that I was able to get the center line of the throttle body and intake ports to line up within +/- 2mm

I finished up the week having nearly completed fitting the velocity stacks.
As you can see there is still a bit of material to be shaved on each of the center stacks. it is pretty easy work I simply ran out of garage time...... I love my wife for putting up with the time that I am down there getting dirty and making a little noise

xoxo ;~)

Waiting for a few -AN bungs for the intake flange. I think it will be better to weld everything in one go. Saves setup time.....

Wednesday, September 21, 2011

54mm Throttle Body Update - 2

Finally took possession of 2 more 54mm throttles and 4x Ducati 999s intake manifolds this week. That puts my count to 4 complete throttles and now it is time to start the manifold fabrication process.

Here is what I have to work with now.

• 2x Injector wire harness complete with Mil spec connectors and air box seals
• 4x 491cc top feed injectors
• 4x shower top velocity stacks
• 4x 54mm Magnetti Marelli throttle bodies
• 4x throttle body manifolds

Also have materials for my throttle body to intake adapter
• 1x 5/8" aluminum plate (manifold flange)
• 1x F22A intake manifold (cut to length for throttle flange)

These next images show the progression of parts, minus the 5/8 adapter plate that will go between the throttle manifolds (black) and F22A manifold flange.

Now it's time to have the throttle shafts machined and cut the aluminum throttle adapter plate to size. Then weld it to the intake flange.......Porting and all the finishing touches after that.

Sunday, August 21, 2011

54mm Throttle Body Update!

As most of you who have been following this blog may know. I was lucky enough to pick up a free PT3 (F22A6) engine. After inspection the head was found to be in perfect working order. So then came the rebuild process as I now needed a new intake adapter for my individual throttle bodies. The PT3 intake ports were much larger than the P0B head that my original throttle bodies were designed for.

Not to say that the 46mm throttles were too small for my original build. However, with the added flow with the new head comes the requirement for a larger throttle plate.

These were a no brainer when it came to updating using a bike throttle body. 54mm throttle bodies should be enough........for now.

I realize that some people may be thinking. With the money that I have spent on all these throttles. I could have bought a set of off the shelf brand name throttles. However, I have still only spent just over $600 on two sets of used throttles and adapter manifolds. That's still 1/3 of a name brand set and $300 cheaper than the rip offs. It's amazing how much you can save when you take the time to learn to design, fabricate and weld. Helps to know a few people as well ;)

The exit port on these throttles is a 95% match to the PT3 intake port. Just the right amount of taper! Anyone familiar with any of Honda's performance intake ports may recognize this shape. Minus the injection port! ;)

They are a much larger throttle in diameter so I have been sent back to the drawing board for a runner design. Picture 4 of these side by side, sorry no pictures yet, I only have two of the 4 so far. Other two are on route.
The shower head w/velocity stack is a much welcome design. The injectors that come with them have a flow rating of 491cc @ 43.5 PSI, and a single stream 15° spray pattern. As a secondary injector, they should help in the higher rpm ranges.
I am currently working on a digital file that I will be sending along with a slab of aluminum to a buddies shop for a trip through his CNC laser table. It will end up as an adapter plate for these throttles. These throttles are not going to end up permanently welded onto runners.

Stay tuned for updates! 

The old 46mm throttles will no doubt become part of another build that I have in mind. Maybe an individual throttle, Boosted 2.2L. Possibly into something with a hatch. A straight line machine.

Tuesday, August 16, 2011

White Housed headlight Update!

Update to my White housed headlights;

Decided to go blue after all!

Original DIY White housing post

Sunday, July 17, 2011

A little more Interior work

Didn't bother getting any felt material this week. So the resin and flet work will have to wait. Instead I took a few minutes to get some more interior prep work done.
Took on the door panels tonight. They are a two piece design. This will actually make the two tone painting process much easier. I am sticking with the Accords original colour scheme.

Once they were taken apart it was time for some more vinyl and foam removal.
There wasn't as much foam on the door panels as the dash. Therefore it was actually much easier to remove.

Took a few minutes to take the window control panel apart as well.
The controls will be getting a good cleaning and the trim piece will be getting a few coats of paint.
If I have some spare time tomorrow I may get the rear door panels done tomorrow night.


Thursday, July 14, 2011

Push Button Start!

Check this one off the list............
No longer a smoker and this car will not have any need for a 12v output socket. So I figured that this would be as good a place as any for my push button start switch to go.

Started off by removing the cigarette lighter housing and trim piece.
Then I had to file the existing trim piece to fit the PBS finish ring. After a few hours of measuring and filing. I finally got it to fit. There are 3 tabs and 3 key ways on the backside of this ring. It was a rather large PITA!
Once that was done it was onto making the mounting bracket for the PBS switch itself. That was to consist of a few bends in a piece of sheet metal.
Then a few more bends and a couple holes drilled and she's ready for paint.
After that was done it was time to set the two mounting screws (with heads cut off) into the back of the trim piece. The reason for doing this is because the lighter socket and housing were used to sandwich this piece in place in the console.
After adding the epoxy I taped the cover in place. This was done to hold the studs straight and true to the mounting holes while the epoxy dried.
Give it a night for the epoxy and paint to dry and the next day was time for a fitting.
Could have been a bit cleaner, but it's all hidden behind the dash..........
.............. I think it looks pretty good from the front.

May start playing with resin this weekend!

Stay tuned!

Wednesday, July 13, 2011

Time for some interior work!

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While I wait for the cash fairy to drop the money off to finish the block. I figured that I would get started on the interior.

Figure the dash is a good spot to start off.
Stripped all of the brackets and vents. Weights in at a whopping 7.2lbs
Then it was skinning time
This was a lot easier than I thought it would be.After about 30 minutes it was completely vinyl free and ready for some sanding and resin.
Had to weigh it just to see... dropped 2lb just from removing the vinyl. However, after I cover up a few unwanted holes and create a custom gauge pod. It will probably end up weighing 10lbs more.
I'm not planning anything too crazy, more function than form.

Stay tuned for more

Tuesday, June 14, 2011

Clean up time!

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With the intake and exhaust guides removed I took the opportunity to clean up the ports a little bit more.

Started with the exhaust............still a little bit dirty, not for long!
The F22A6 head really doesn't have much to remove when it came to the valve guide humps. I had the bulk of the guide humps removed fairly quickly.
 Took them up to an 80 grit for now.......they will be mirror finish when completed.
The intake had less guide material...
However the port itself was an odd shape. The long radius had a bit of a dead zone directly behind the valve guide.The transition from the throat into the seat has a pretty good step as well.
Once I get a flow bench setup I will spend a bit more time figuring out what to do with that dead zone for now I removed a bit of material from the front of the guide only.
 Looks like I may have to add some material to fill that dead spot....only time on the bench will tell.
For now the exhaust ports will get finished and the intake ports will have to wait.

Time to start wet sanding

Sunday, June 12, 2011

Little bit of Guide Work

Cranked up the old oven to 150°C and got the workbench prepared to remove a couple valve guides tonight.

The exhaust side was a bit more work than the intake side. Now I know that if I get into doing this on a regular basis. I will have to invest in an air chisel with a 5.5mm guide bit. Too many trips back and forth to the oven for this cat.

Exhaust side removed....took a few swings of a hammer to get them out. The added surface area on the cylinder head for the exhaust guide acts as a heat sink. This is a good thing for cooling the exhaust valves. Not so good for removing the exhaust guides!
 Intake side removed, fairly easily as there is approximately half the surface area to overcome.
All ready for a bit more porting........
Next update should have all these ports ready for a valve job and new guides.

Keep the AFRs low