Thanks, its going to be a tight fit.

Like I said you're going to have to check up on the dimensions first before you cut anything. Oil pedestal is correct although you should probably weld some fittings directly onto to the iron base instead as it's a very very tight fit with the transmission line there(PITA). No the second plate is actually the MAF base(which is dimension correct) to weld to the filter intake. Trust me you do need the damn MAF, not only because you are using the stock tb but because without it the alternator doesn't charge the battery correctly(only like 10-11volts)/pretty fcuked up right? That was a bitch to find out!!! Is there anything else you need?

Nice!...I checked the dimensions and they were a bit off...I also had issues importing it into Mastercam so I decided to draw my own for the throttle flange. I will use the oil one though...it seems right. I appreciate the help!

I will post some pics of the CAM process as well as the cutting...:)

Chris

Here is the CAD/CAM process...

Chris

First measuring the BRE throttle with the CMM...
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Then drawing...

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Ready to Cut...

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Simulation...now to cut some actual metal...

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http://i679.photobucket.com/albums/v...n/IMAG0846.jpg

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First side done! Now need to do the backside...will pick back up tomorrow.

Cheers!

Chris

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Another shot...

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Lucky bstard...

Here is modeling for the other side...

The plan is to taper all 3 diameters into the 3.5" throttle hole from the other side and then make a cut that encompasses the areas where they meet so the flow is not disrupted through there. It isn't very clear in the simulation but it will make sense when you see the finished part.

Cheers!


Here is the drawing of the "common areas" between the RX-8 throttle and the 3 butterflies from the BRE throttle.

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We begin by tapering in the diameters

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Chamfer the backside profile...

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And then cut the common areas...

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Finished! Transitions look great...:)

Chris

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Mocked up on both throttle bodies just to check transitions and finally thrown on the UIM...:)

C

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Updated list...

Machine front cover - STARTED
Weld front cover
Front cover oil line
Machine front pulley spacer
Driver engine mount finish
Pass engine mount finish
Finish LIM (welding, holes etc) - STARTED
Drill UIM bolt hole
Make Throttle body adapter-DONE!
Oil filter Pedestal (machine, relocate, whatever)
Modify Water Pump Outlet - STARTED
Oil pan and pickup
Alternator Adapter
Custom Alternator Tensioner
Relocate OEM ECU to Firewall
Install Wastegates
Make Downpipe - STARTED
Make Wastegate dump
Fuel rail mod
Make/Modify Fuel lines
Make Turbo Oil lines
Make Radiator cover plate
Water reservoir
Intercooler mount
Cut Intercooler piping
Weld Intercooler piping
Weld BOV
Replace exhaust sleeves
Machine engine for studs/Dowels
Make Ignition Bracket

Just thinking maybe you should have opened up the intake manifold and removed all the separators since you're now going to use a single tb(PITA)?

Looking good!

Would love to see a ball mill in there though :nod:

lots of work. would it be easier to have swapped chassis than motors?

Perhaps... But I'm not sure what I will do in the future... I can still blend the area that's exposed... Not too worried about that.

C

Hehe, thanks. I have ball end mills but used a corner radius end mill instead because I could use it to mill flat if I wanted to. It probably looks rough in the pics but the corner radius is 1/8 which blends the steps nicely when you run your finger through it... It just looks ribbed which I like :)

C

not really, isn't that the point of a swap?

I'm putting more work into this than what is needed because I want to... It's part of the fun. I couldve done the swap with way less work but why?

C

Ribbed for his pleasure. Sorry I just had to...

HAhaha...LOL

Boy did I walk right into that one...I don't blame you...

C

Finished reinforcing the Passenger Side Engine Mount. Its all 1/4" Steel and weights a ton but I need it to hold all that I can throw at it...

Cheers

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Worked on the water outlet a bit...waiting for all the aluminum welding to be ready before I work on that...

Chris

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Put an hour or so into the Alternator pulley. I decided that I wanted to keep it in the stock location, from here, moving it forward is the only option. I settled on making an adapter bracket/spacer to move the Alternator fwd so it can be turned with the front crank pulley instead of the rear one as is stock. The only problem then would be that the front pulley is 19% bigger than the rear one which would mean the alternator would overspin so I started working on a 20% larger alternator pulley to slow it down to stock levels. Of course, while Im at it, I will mill a rotor shape into the front of it :D

Cheers

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Ok...at first when I was reading this thread it was looking like the average guy's RX8 conversion...then you busted out the CAD and water-jet cutting machine (don't know the real name...lol) and now I'm feeling ummm....betrayed lol. It doesn't mean I'm not in awe of the work...because I am...and I can't wait to see how this turns out!

where do you work mate ? I think you have some of my new favorite tools !!

Hehe...I am just the average guy...I just happen to work with these tools :D

Chris

p.s. its a milling machine ;)

I own a manufacturing facility, we machine medical and aerospace components...for the past year and a half I was so swamped with getting the business up and running that I hadn't touched any of the machines to do anything for me, this year will be different :)

Chris

Quick update, my 3" couplers came in...:)

Cheers

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Intercooler came in...not to big, not to small, just perfect for my goals without sacrificing spool...:)

Chris

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Worked on the CAD/CAM for the pulley...will hopefully run it sometime this weekend...:D

Chris

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^ Nice man!


Make two of them, one for you and one for me..... please :)

Hehe...I don't think it would work for your application, it probably won't spin fast enough. I made it bigger to reduce the speed of the Alternator because I will be running it off a bigger pulley on the crank.

:)

Chris

Its also only 4 ribs instead of the usual 5 because it will run off the front pulley which only has 4...

Chris

Finished the Alternator Pulley today...its hard to photograph due to the reflection but its got tons of details and looks very good...:)

C

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Here it is next to the stock sized one...19% bigger and only 4 ribs...mission accomplished...:nod:

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Nice!!!! do you know when my special package is coming in?

Oh well!

pulley came out great!

If you ever make any in the stock size with the rotor then count me in for one!

great build bro!

Will do for sure!

C

This is freaking beast. :icon_tup:

Subscribed and watching with interest! Good luck with everything along the way!!! :nod:

Decided to polish the face of the rotor on the pulley...the pics don't do it justice, had to put a pen in the picture for it to be noticed but it looks like a mirror in person. Has great contrast with the rest of the machined surfaces...:)

Chris

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I finally got around to making the two holes for the Wastegates and tacking them on to check fitment. Now I need to verify everything fits in the engine bay and then pull everything out and finish welding the down pipe and the wastegate flanges.

Cheers!

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pretty bro.

Updated ToDo list:

Machine front cover (counterweight/alternator) - STARTED
Weld front cover
Front cover oil line
Machine front pulley spacer
Driver engine mount finish - STARTED
Pass engine mount finish - DONE
Finish LIM (cut, welding, holes etc) - STARTED
Make 2 extra injector Bungs for LIM (RX-8 Fuel rail has 4)
Drill UIM bolt hole - DONE
Make Throttle body adapter-DONE!
Oil filter Pedestal (machine, relocate, whatever)
Modify Water Pump Outlet - STARTED
Oil pan and pickup
Make Alternator Pulley - DONE
Make Custom water pump Tensioner
Relocate OEM ECU to Firewall
Install Wastegates - STARTED
Make Downpipe - STARTED
Make Wastegate dump
Fuel rail mod
Make/Modify Fuel lines
Make Turbo Oil lines
Make Radiator cover plate
Water reservoir
Make radiator lines
Intercooler mount
Cut/Tack Intercooler piping
Weld Intercooler piping
Weld BOV
Replace exhaust sleeves
Machine engine for studs/Dowels
Make Ignition Bracket

Thanks!

Awesome work! Good luck with your project.

Threw everything back in the car to check for wastegate and downpipe fitment and found that the wastegates were fine but the downpipe would be a bit of a problem. Essentially, I got it in there but it would be so close to everything that it would be nothing to but headaches and vibrating noises so I made marks in the problem areas and I pulled the DP off and "compressed" some of the areas in my big vise. The result is at least 1/2" of clearance everywhere and not so much loss in flow :)

In the process I also noticed that moving the alternator forward to use the front pulley while keeping in its general oem location would cause the front belt to interfere with the waterpump pulley...this means I will probably have to throw the alternator over to the driver's side (as in the last picture) regardless of my desire to keep it in the middle of the engine.

Cheers!

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Finished welding the wastegates onto the manifold...:)

C

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Worked on the wastegate Dump today...I still want to recirculate it back into the exhaust but for now will just dump it mid way. I am unsure if I will be able to package a reroute into the exhaust somewhere so this will work for now. I would like to add that that flex pipe, which is a necessary evil with this setup, is the hardest thing I have ever had to weld...it just wanted to melt away so the welds aren't pretty at all...Im just happy it sealed...lol I couldn't use a regular flexible section due to the available space.

Cheers!

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look at that dent. Something for me to look forward to.