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Making my own EFI intake... The First Casting


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#1 Derek

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Posted 07 February 2008 - 06:05 PM

Well I finally got some time to get over the foundry to pour the first manifold.
If you are new and need to come up to speed here's a link to the design stage
http://forums.hybrid...ad.php?t=121021

And a link to the pattern making
http://forums.hybrid...ad.php?t=121478


Here is the core assembly all glued together with the stainless tubes and the bronze bushings in place


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This is the pattern with the flask around it.
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Ramming the sand

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This is the drag or bottom of the mold with the pattern removed

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Setting the core. Cores makes castings hollow.

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We decided to do a dual pour. Don't try this at home! I'm running the camera by the way.

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The moment of truth.

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I'm really happy with this
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I ran out of time but tomorrow I'll shake out the cores and post a few more pics of the casting.


Derek

#2 MJLamberson

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Posted 07 February 2008 - 06:10 PM

I dont know jack about this... or anything really, but I do know that that is really way cool! great job!
-Michael Lamberson
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1976 280z, parted out
1977 280z, RIP, PARTING OUT! TURBO STUFF!http://forums.hybrid...ad.php?t=150948



#3 OlderThanMe

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Posted 07 February 2008 - 06:19 PM

Wow!
I've been following your progress from the beginning and this is really cool!

Hope you can finish the other half soon!
OTM
[URL="http://forums.hybridz.org/showthread.php?t=137080"][/URL]

#4 jeffer949

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Posted 07 February 2008 - 06:48 PM

holly &$&$&$ that is awesome derek i need to make it out to ocala to see that thing. or you could just take a detour and go back to ocala though daytona!!!! lol looks awesome... hrmm i might have to get one of these when your done....well i guess i will have to cut it and weld on a plenum though. cause you know i cant live with out boost!!!!
[SIGPIC][/SIGPIC]1974 260ZT known as Stella- the temperamental bitch

#5 Evan Purple240zt

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Posted 07 February 2008 - 07:26 PM

That is ridiculously cool. I am so glad your seeing this project to the end.

Evan
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1972 240z RIP

#6 G.I.jonas

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Posted 07 February 2008 - 07:30 PM

Looks like trumpets?,thats a manifold?-pretty cool anyways :-)
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#7 sweetleaf

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Posted 08 February 2008 - 12:35 AM

Nice fab fork... I've had my hand at casting, it's definately a lost art.

#8 olie05

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Posted 08 February 2008 - 01:31 AM

wow. that will definitely be the sexiest itb setup on an l6.
"I heard and smelled your car before I saw it." -innocent bystander

#9 Derek

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Posted 08 February 2008 - 04:06 AM

Thanks guys. I'm really happy with the way it turned out.


holly &$&$&$ that is awesome derek i need to make it out to ocala to see that thing. or you could just take a detour and go back to ocala though daytona!!!! lol looks awesome... hrmm i might have to get one of these when your done....well i guess i will have to cut it and weld on a plenum though. cause you know i cant live with out boost!!!!



That's why they make band saws and tig welders!


Looks like trumpets?,thats a manifold?-pretty cool anyways :-)


Well I figured if it doesn't work as a manifold I'd park a seal behind it, teach him a tune and go to work at a circus!


I'll knock the cores out later this morning and post a few pics

Derek

#10 TimZ

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Posted 08 February 2008 - 09:37 AM

We decided to do a dual pour. Don't try this at home! I'm running the camera by the way.

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Pouring molten aluminum with a short sleeve shirt and no gloves... that is what I'm looking at there, right?
:shock: :shock: :shock:

Manifold looks great, btw!
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Information is not knowledge
Knowledge is not wisdom
Wisdom is not truth
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#11 Derek

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Posted 08 February 2008 - 09:53 AM

I wondered what took so long for someone to pick up on that!
Seriously both of these guys (one is the owner) have been doing this continuously since both were in high school and they're both in their early fifties. The first time I saw it I couldn't believe it because I'm like mister safety at my shop. Now when they pour bronze and iron it's a whole different story. They look like spacemen.

I don't want this to turn into a debate about foundry safety so if people want to go that direction then let's start a new thread.

Thanks
Derek


Pouring molten aluminum with a short sleeve shirt and no gloves... that is what I'm looking at there, right?
:shock: :shock: :shock:

Manifold looks great, btw!



#12 tfreer85

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Posted 08 February 2008 - 10:18 AM

Derek, do you know what type of furnace they are using? A lift out crucible furnace? Tilting furnace or cupola furnace? I'd love to see some pictures of their setup. Also what type of sand are you guys using? I've been reading a lot of Steven Chastains book's with a lot of enjoyment and had always wanted to do what you're doing. http://stephenchastain.com/store.htm

Thanks,
Tyson
Tyson

#13 Derek

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Posted 08 February 2008 - 10:35 AM

Now for the small world award. Steve is a frequent visitor to the foundry. He's known the owner for quite a few years and I've met him a few times. He's really a great guy and has a firm handle on the home brew "build it on a dime" mentality.
The foundry uses induction melters. They use Olivine green sand. I've got a bunch more pics that I'm going to be uploading to a gallery in the next few days. I'll let you know when I've got it done.

I'm sure we can work Kevin Bacon in here if we try hard enough!

Derek

Derek, do you know what type of furnace they are using? A lift out crucible furnace? Tilting furnace or cupola furnace? I'd love to see some pictures of their setup. Also what type of sand are you guys using? I've been reading a lot of Steven Chastains book's with a lot of enjoyment and had always wanted to do what you're doing. http://stephenchastain.com/store.htm

Thanks,
Tyson



#14 DemonZ

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Posted 08 February 2008 - 10:54 AM

That is so freaking cool! Can't wait for the production run :)

#15 tfreer85

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Posted 08 February 2008 - 10:59 AM

Now for the small world award. Steve is a frequent visitor to the foundry. He's known the owner for quite a few years and I've met him a few times. He's really a great guy and has a firm handle on the home brew "build it on a dime" mentality.
The foundry uses induction melters. They use Olivine green sand. I've got a bunch more pics that I'm going to be uploading to a gallery in the next few days. I'll let you know when I've got it done.

I'm sure we can work Kevin Bacon in here if we try hard enough!

Derek


Thats awesome!!! I just ordered another one of his books, and decided to buy footloose too...(jk, no footloose) Can't wait to see the pictures and the finished product!! Jealousy and scheming is setting in :D .

Tyson
Tyson

#16 BobbyZ

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Posted 08 February 2008 - 12:00 PM

That is beautiful, gonna be a cool unique addition to your car!

#17 JustinOlson

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Posted 08 February 2008 - 12:09 PM

Wow!

#18 MrZ

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Posted 09 February 2008 - 07:01 AM

Wow! are they planning on making a brand new L series head and block? This might be good!!!!!!

They can make crate engines soon.
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#19 zguy36

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Posted 09 February 2008 - 07:37 AM

They would be derek, he's the one who did all of the work to make this manifold

#20 speeder

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Posted 09 February 2008 - 12:50 PM

That looks so sweet, Derek - Can't wait to see those finished and installed!
Rick Bowers
'77 280ZT (Not as fat as I thought) - Awaiting 260ci Twin Turbo Buick Stage II - Finally out of machine shop jail after 2+ years!
'78 280Z (Soon to be for sale)
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My build thread: http://forums.hybrid...ad.php?t=136300
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Rick's 280ZT AKA: "Porkchop"




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