Chippy63 Posted November 4, 2019 Share Posted November 4, 2019 Im making another pair of manifolds and this is the earlier part of the build i couldn't show in the other thread due to lack of photos. Link to comment Share on other sites More sharing options...
Chippy63 Posted November 4, 2019 Author Share Posted November 4, 2019 Squeezing round tube to square, with a vise and former after annealing the tube. Link to comment Share on other sites More sharing options...
Nick Jones Posted November 4, 2019 Share Posted November 4, 2019 That's clever. Like that Link to comment Share on other sites More sharing options...
Chippy63 Posted November 4, 2019 Author Share Posted November 4, 2019 Thanks Nick, surprisingly small amount of effort to squeeze these Ali tubes, not sure how it would work on mild steel. Link to comment Share on other sites More sharing options...
RogerH Posted November 5, 2019 Share Posted November 5, 2019 Hi Chippy, I assume you have a square section male that is pushed into the round Ali and the welded steel box stops it at the correct dimension. You may be lucky and achieve the same with mild steel. It is possible that it may split at the corners. Or you could hold the male former in a vice and gently push down on the round tube; at the same time using a wooded/rubber hammer panel beat the tube to shape. Mild steel likes a good beating. Roger Link to comment Share on other sites More sharing options...
Chippy63 Posted November 5, 2019 Author Share Posted November 5, 2019 Roger i have a square tapered punch to sort out the square end. As for the stop its when the round die meets the tapered outer box. Steve Link to comment Share on other sites More sharing options...
Chippy63 Posted November 6, 2019 Author Share Posted November 6, 2019 I didn't have my band saw the first time i cut the injector bungs, this is a lot easier now. Link to comment Share on other sites More sharing options...
Chippy63 Posted November 6, 2019 Author Share Posted November 6, 2019 I have made a slight change this time by shortening them down to the shortest i think i can go before i get welding issues around the edge. it will allow for longer injectors and not shroud the tip so much. Link to comment Share on other sites More sharing options...
Nick Jones Posted November 6, 2019 Share Posted November 6, 2019 Like your holding tool trick.... might have to plagiarise that! Didn't have the band saw last time I cut the pockets...... Link to comment Share on other sites More sharing options...
Chippy63 Posted November 7, 2019 Author Share Posted November 7, 2019 Go for it Nick, im finding so many uses for my band saw. I reckon its almost as essential as a big hammer Link to comment Share on other sites More sharing options...
Chippy63 Posted November 9, 2019 Author Share Posted November 9, 2019 Here i'm using a jig to get the position of the injector sockets on the inlet tubes. The first time i drilled the tubes after i had welded on the sockets but this pulled up a lot of Ali which made a mess of the important part where the o rings seal which then had to be polished so this time i'm going to pre-drill the tubes where the injectors are before i weld the sockets on. Link to comment Share on other sites More sharing options...
Nick Jones Posted November 9, 2019 Share Posted November 9, 2019 Best way to do it I think. I made a jig for the Spitfire manifolds. Yours looks rather better though. Are you taking orders? Link to comment Share on other sites More sharing options...
Chippy63 Posted November 9, 2019 Author Share Posted November 9, 2019 36 minutes ago, Nick Jones said: Best way to do it I think. I made a jig for the Spitfire manifolds. Yours looks rather better though. Are you taking orders? This one is a swap with Neil Brown, may be you know of him has lots of triumphs Tr250 with efi stag engine. 2.5 estate with stag engine. A stag with efi ,a 2 door Toledo with rover v8 . Anyway im building him a set up like mine and he his doing the same work on a pair of heads of mine as he did to his which has achieved 250 bhp and 220ftlb of torque once fitted with fast road cams and 4-2-1 exhaust manifolds. Link to comment Share on other sites More sharing options...
Nick Jones Posted November 10, 2019 Share Posted November 10, 2019 AKA The Flying Farmer? 250bhp is more like the output a 3L V8 should produce! Hope the rest of the drivetrain is feeling strong..... Link to comment Share on other sites More sharing options...
Chippy63 Posted November 10, 2019 Author Share Posted November 10, 2019 4 hours ago, Nick Jones said: AKA The Flying Farmer? 250bhp is more like the output a 3L V8 should produce! Hope the rest of the drivetrain is feeling strong..... Mine is, Neil is using std stag stuff and its holding together ok and he seems to do plenty of miles. As you say the flying farmer thats him. Link to comment Share on other sites More sharing options...
Nick Jones Posted November 10, 2019 Share Posted November 10, 2019 12 minutes ago, Chippy63 said: Neil is using std stag stuff and its holding together ok so what are you using......? Link to comment Share on other sites More sharing options...
Chippy63 Posted November 10, 2019 Author Share Posted November 10, 2019 1 hour ago, Nick Jones said: so what are you using......? Well I've still got the stag OD box but I've got sd1 clutch cover with Tilton CSC, larger propshaft about 100mm iirc and a complete BMW e30 rear subframe conversion with disc brakes , CJ driveshafts and a whole host of diff ratios available to me. Currently 1:3.46 but have a 1:3.64 in the work shop. Steve Link to comment Share on other sites More sharing options...
Nick Jones Posted November 10, 2019 Share Posted November 10, 2019 BMW rear is a good call. Wonder about the Stag ‘box...... I know it’s the strongest of the big T boxes but even so...... Link to comment Share on other sites More sharing options...
Chippy63 Posted November 10, 2019 Author Share Posted November 10, 2019 2 hours ago, Nick Jones said: BMW rear is a good call. Wonder about the Stag ‘box...... I know it’s the strongest of the big T boxes but even so...... I have gathered other parts(bell housing and adaptor plate) with the view to getting a stronger box like one from a supra for future transplant. Link to comment Share on other sites More sharing options...
Nick Jones Posted November 10, 2019 Share Posted November 10, 2019 W58 is said to be good for 300 bhp so would be a decent choice - if you can find one..... were also used in certain Lotii and can sell for less as people don’t realise the bell housing is the only difference. Link to comment Share on other sites More sharing options...
Chippy63 Posted November 30, 2019 Author Share Posted November 30, 2019 So Jig now made to hold the inlets whilst i mill the oval injector holes. Link to comment Share on other sites More sharing options...
Chippy63 Posted November 30, 2019 Author Share Posted November 30, 2019 Link to comment Share on other sites More sharing options...
Chippy63 Posted November 30, 2019 Author Share Posted November 30, 2019 Injector sockets tacked in place Link to comment Share on other sites More sharing options...
Nick Jones Posted November 30, 2019 Share Posted November 30, 2019 Great work Doing it properly, which is nothing like the way I do it...... Link to comment Share on other sites More sharing options...
Chippy63 Posted December 1, 2019 Author Share Posted December 1, 2019 18 hours ago, Nick Jones said: Great work Doing it properly, which is nothing like the way I do it...... Don't know about that Nick, but I having fun doing it. I don't have a clue on the mill but its all a bit of a steep self learning curve. Link to comment Share on other sites More sharing options...
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