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Dale M. wrote:may end up 42 or 44 mm

That's all certainly doable. I'll get some pricing together. Will they all be the same bore diameter, (42 or 44mm)?

I could do them for $40 a set, (of 2), if the bores are all the same. $50 a set if they are different. This doesn't include shipping.

I would go with 40 or 42mm ID holes, 40 would be the best.

supaninja wrote:I would go with 40 or 42mm ID holes, 40 would be the best.

I can start them if you want.
If you both want some, you might save a few bucks.

Oops. Double post.

Check out ebay. A guy is selling DCNF and IDA pattern flanges already but no IDF. I would want mine in steel not aluminum for ease of proto type fabbing. Actually, I would take a set of both. Most people building their own intakes that these are geared towards will be over 42mm ID. I say make them 44mm to make them more "universal".

Do you want a set made from steel Steve?

I have not got my flanges for my TB's yet so I don't have definitive size for set I'm looking for, but price is certainly reasonable for a set.... Would also like somebody to double check my dimensions just to be sure everything "fits" (other than main bore diameter) ...

Dale

If you have 38 or 40mm gsxr TB's the spigot flanges have a 40mm ID, 42mm hole is getting really close to the sealing surface (a gasket would probably solve that). There is lots of variations with all our setups, I'm going to be making my own weld plates, hole saw and drill press, kind of primitive but should "work".


I'm having a wild hair to learn how to sand cast, I can see it already: type 1 mani, type 3 shorty, type 4 mani, type 4 shorty, 80mm center to center version for all of them...holy plugs batman! It would be awesome to have good inexpensive option.

supaninja wrote:I'm having a wild hair to learn how to sand cast,

A friend and I have been doing exactly this. It's not as cheap as I thought it would be, but there are a lot of options for sure.

awesome, i'm going to be bothering you with questions....alot!

supaninja wrote:
I'm having a wild hair to learn how to sand cast, I can see it already: type 1 mani, type 3 shorty, type 4 mani, type 4 shorty, 80mm center to center version for all of them...holy plugs batman! It would be awesome to have good inexpensive option.

Gads thread took another left turn...... Try Lost wax method (investment casting) its more precise and a lot cleaner, and your "plug" is made of wax so you can sculpt it any way you want and if you make a silicone or latex mold off "plug" you can cast hundreds of units by just creating new wax plug(s) for each casting run.... Probably build your own forge, and centrifugal or vacuum casting machines and use beer cans and old pistons or aluminum lawn furniture for metal....

I though about doing exactly this with a TB with WEBER IDF base.... Can't see why they are $600-1000 for a set for TB when once development work is done the should be about $250 a pair with everything except injectors and TPS... Once casting process is done a single setup for CNC machine should clean up any "details"... Maybe I'm just naive but "manufactured" TB really seem to be a "rip" to me....

IF you are going to cast up something, do a all in one unit on concept of these...

http://www.thesamba.com/vw/classifieds/ ... id=1200622



Love to find a set of these in a "barn find" would be tits for conversion to EFI...

Dale

I was thinking about TB's down the road but the GSXR stuff is so abundant and cheap(My TB's with injectors was only $30). The most elegant approach would be to purposely make manifolds purposely built for them. Include injector bosses in the most ideal location and keep the costs down, I think this package will be the future for our hobby. I am going to look into the lost wax method, sounds like better way then sand casting.

To further derail this post....

Dale M. wrote:Try Lost wax method (investment casting) its more precise and a lot cleaner, and your "plug" is made of wax so you can sculpt it any way you want and if you make a silicone or latex mold off "plug" you can cast hundreds of units by just creating new wax plug(s) for each casting run.... Probably build your own forge, and centrifugal or vacuum casting machines and use beer cans and old pistons or aluminum lawn furniture for metal....

I think you'll find this to be much more expensive than machining an adapter plate, whether on a CNC mill or a drill press at home. Greensand casting is fairly cheap to involve yourself with, but the patterns, (for either method), is rather time consuming. FWIW, greensand, or even petrobond sand, is quite a bit cheaper than investment casting materials. Another alternative would be the lost styrofoam method of casting aluminum. Although, still very time consuming, it's very affordable to do for a very small lot of parts.

supaninja wrote:The most elegant approach would be to purposely make manifolds purposely built for them. Include injector bosses in the most ideal location and keep the costs down,

That would, indeed, be sexy, but machining would still be required. I'd love to see these cast and posted up here.

Dale M. wrote:IF you are going to cast up something, do a all in one unit on concept of these...

http://www.thesamba.com/vw/classifieds/ ... id=1200622

Image

Those are sand cast BTW. Likely not greensand, but petrobond instead. The cores used to cast those must be a sight to behold.

came across this at Ross Machine Racing:



A bit stiff at $50, but they look good