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Post by ScrapinSTi on Mar 2, 2009 21:57:38 GMT -5
So the rally car needs to run a 32mm restrictor in it.... Either A.... We can buy one that is ridiculously expensive, and a pain to install... or I can make one! So I found a piece of 3.5" diameter 6061 aluminum at work, and thanks to some kickass dimensions and photos from the guys at DSG, I went to work... First, i put the piece in the lathe, and flattened the face... Then, I created the 32mm inner bore. And after that, its time to make the outer diameters... And another step down... And i was too tired to do anymore... Tomorrow i'll figure out my angles for the outer and inner tapers, and make my way back into the shop to finish it up later on this week... And this is an example of what the final product will look similar to (Except this picture is of a 40mm restrictor instead of a 32mm)
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Post by skimobile on Mar 2, 2009 22:05:42 GMT -5
Lookin good! Doesn't the restrictor have to be lock wired into the turbo inlet once installed?
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Post by ScrapinSTi on Mar 2, 2009 22:22:52 GMT -5
The rules say:
5. The mounting of the restrictor onto the turbocharger must be carried out in such a way that two screws have to be entirely removed from the body of the compressor, or from the restrictor, in order to detach the restrictor from the compressor. Attachment by means of a needle screw is not authorized. For the installation of this restrictor, it is permitted to remove material from the compressor housing, and to add it, for the sole purpose of attaching the restrictor onto the compressor housing. The heads of the screws must be pierced so that they can be sealed.
I plan on drilling two #6 through holes in the compressor housing & the restrictor, then just throw a couple of either buttonhead or flat head cap screws in there... Even though when it has the shoulder on there, there will be no way for it to move around once installed.
Would be nice if i could find a junk evo8 compressor housing to use for mockup... I'm working completely from photos & measurements.
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Post by Team Avanti on Mar 3, 2009 0:07:02 GMT -5
very nice and good luck
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Post by antagonistace on Mar 3, 2009 11:11:27 GMT -5
Very nice! First a map light and now this.......are you MacGyver?
Will you guys have a on-board camera?
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Post by ScrapinSTi on Mar 3, 2009 13:24:39 GMT -5
Yup... After I finish this I will move on to the Navigator Footrest, which will be fully adjustable for different heights, and possibly a hydraulic handbrake... And yeah we have a camera that we use... but as you can see in this video... www.youtube.com/watch?v=kYCJMCGkn-I&feature=channel_pageIts too high.. I need to find a way to mount the camera lower... Currently I use a Manfrotto Magic Arm like this With a Manfrotto super clamp on the roll cage I might be able to mount the magic arm differently to get the camera a little lower, but i dont know how much lower i'll be able to go without being blocked by the roll cage. And once the stage rallies start, we'll make sure to have the intercom plugged into the camera as well so you can hear me yelling at the russian to turn LEFT not right! ;D
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Post by antagonistace on Mar 3, 2009 17:38:08 GMT -5
Ugh......Noah.......I just saw your "Shopping Cart" video..........If you ever run for President, you have my vote. Just seen the car wash stuff too. You sir, are legendary. The cam is too high, but I can still see the pathway. I just got done with my cam mount mock up. Fits the M6 good, but I need to fab a bracket for the honda. PS: We almost look like we could be brothers. Exept my sideburns are more badass! Here is a recent pic of me. Evny mah sideburns! i494.photobucket.com/albums/rr304/RSpec911/l_a32111d40b71f318cdb3fc0d8f645a74.jpg
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Post by ScrapinSTi on Mar 3, 2009 23:22:24 GMT -5
Please dont insult me like that... ;D j/k... Yeah... i still have more videos to upload from the scavenger hunt this year... Hoping to get back into the machine shop tomorrow and finish up...
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Post by ScrapinSTi on Mar 5, 2009 9:44:22 GMT -5
the basic CAD cutaway courtesy of my friend Matt... Need to change a few things... This was based off a 32mm restrictor, but it will actually be 34mm, and i'm going to move the taper higher in the restrictor, and shorten the length of the restrictor from 5mm to 4mm.
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Post by ScrapinSTi on Mar 9, 2009 21:28:29 GMT -5
Tonight we finished it up... First we cut the outside taper and polished it using emory cloth, then scotch brite, and some mothers polish.. Then we cut the first inside taper, and polished again... Then flipped it, chopped off the excess with the band saw, and cut the taper on the other side... Some finished shots... Outside Smooooootthhhh finish.. Lower half (Closer to turbo) Upper Half.. All in all, it came out very nice... And WELL within spec... Minimum distance of restrictor is 3mm, we are about 5.5...
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