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Originally Posted by ChrisRX8PR
(Post 11028370)
Don't forget your turbo exits to 5" on the hot side so you will need a reducer. :)
Chris |
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Originally Posted by ChrisRX8PR
(Post 11028943)
Oh wow, thanks Man! I was going to have to draw those to be able to program them, Now I can just work on CAM side of things...
I recognized the oil pedestal one and the other ones seems like its the bolt pattern from the BRE mani with a round hole for my throttle...am I correct? Thanks a million! Chris |
Originally Posted by dznutzuk
(Post 11029212)
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?
I will post some pics of the CAM process as well as the cutting...:) Chris |
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Here is the CAD/CAM process...
Chris First measuring the BRE throttle with the CMM... Attachment 718123 Attachment 718124 Then drawing... Attachment 718125 Attachment 718126 Attachment 718127 Attachment 718128 Attachment 718129 Ready to Cut... Attachment 718130 |
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Simulation...now to cut some actual metal...
Attachment 718131 Attachment 718132 http://i679.photobucket.com/albums/v...n/IMAG0846.jpg Attachment 718133 Attachment 718134 Attachment 718135 Attachment 718136 |
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First side done! Now need to do the backside...will pick back up tomorrow.
Cheers! Chris Attachment 718137 Attachment 718138 Attachment 718139 Attachment 718140 Attachment 718141 Attachment 718142 Attachment 718143 Attachment 718144 |
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Lucky bstard...
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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. Attachment 718146 We begin by tapering in the diameters Attachment 718147 Attachment 718148 Chamfer the backside profile... Attachment 718149 Attachment 718150 And then cut the common areas... Attachment 718151 Attachment 718152 |
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Finished! Transitions look great...:)
Chris Attachment 718153 Attachment 718154 Attachment 718155 Attachment 718156 Attachment 718157 Attachment 718158 Attachment 718159 Attachment 718160 Attachment 718161 Attachment 718162 Attachment 718163 |
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Mocked up on both throttle bodies just to check transitions and finally thrown on the UIM...:)
C Attachment 718164 Attachment 718165 Attachment 718166 Attachment 718167 Attachment 718168 http://i679.photobucket.com/albums/v...n/IMAG0888.jpg Attachment 718169 Attachment 718170 Attachment 718171 Attachment 718172 |
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 |
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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)?
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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?
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Originally Posted by dznutzuk
(Post 11030838)
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)?
C |
Originally Posted by gusfd3s
(Post 11030845)
Looking good!
Would love to see a ball mill in there though :nod: 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
Originally Posted by Efinity
(Post 11030849)
lots of work. would it be easier to have swapped chassis than motors?
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Originally Posted by ChrisRX8PR
(Post 11030957)
you run your finger through it... It just looks ribbed which I like :)
C |
Originally Posted by dznutzuk
(Post 11031316)
Ribbed for his pleasure. Sorry I just had to...
Boy did I walk right into that one...I don't blame you... C |
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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 Attachment 718173 Attachment 718174 Attachment 718175 Attachment 718176 Attachment 718177 Attachment 718178 |
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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 Attachment 718179 Attachment 718180 Attachment 718181 Attachment 718182 Attachment 718183 Attachment 718184 http://i679.photobucket.com/albums/v...n/IMAG0909.jpg Attachment 718185 Attachment 718186 |
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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 Attachment 718187 Attachment 718188 Attachment 718189 Attachment 718190 Attachment 718191 |
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!
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where do you work mate ? I think you have some of my new favorite tools !!
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