Derek

Wow Jeff you had quite the adventure! Glad it all worked out for you. Derek

Interesting idea. He's forming the screens then poring a silicone boot around them. I'm still leaning towards using the wire cloth and foam at this point. The main thing I'm rethinking is the method of attachment. Maybe I can incorporate this guy's rubber boot method with my wire cloth and foam. I have all the equipment to do silicone molding so that wouldn't be a problem. Thanks for the link and idea. Derek

So let it be written, so let it be done! I'll make the pad longer and drill it accordingly. Derek

Let me know on that if you don't mind. I found filter foam from UNI Filter. They offer sheet foam that's .375" thick and 60 PPI density. They also offer 30 PPI as well. I think the idea is on dirt bike is to make a sandwich of the two. I'm going to call UNI and see if they have any suggestions on this. I calculated the area of the filters and I'm going to be hard pressed just to get 60 square inches of surface. As the filters start to plug will that change the AFR and will Megasguirt see it? Just thinking out loud here but it would be nice if there was a way to have Meggasquirt send an error when the condition reached a certain threshold. Something along the lines of "hey butwipe clean your filters!!!" I'm planning on running a carputer so I'll have the ability to monitor the readings anyway. If I try really hard I can complicate this enough to where I'll never get it done!!!! Derek

Hi Phar Yea some gussets on the tabs would probably be a good idea. Thanks. The IAC is from a 1992 Jeep 4.0. Hi Tony I tried to design this as a universal style block so it could be adapted to other applications that wanted a stand alone IAC/Vacuum log. Derek

What's interesting to me is they offer the 3D cad files for download and seem to encourage people to make a test model. http://www.tcengine.com/Parts.html You don't see that happen too much! Derek

Sensei Tony D (among others) Recommends using a separate Idle bleed screw as opposed to cracking the throttle plates or using the IAC. Apparently on ITBs you want the butterflies completely closed at idle. I like it because I can easily increase the idle without jumping into megasquirt. Derek

Well I decided to start designing the vacuum log. I wanted to incorporate the IAC and the main idle screw. Then I figured why not mount the balance needle valves on there as well. The individual lines will run over to each boss on the bottom of the throttle body. The lines will be hidden under the web of the manifold. This would make setting them a whole lot easier. It also looks pretty cool! The foot print is about 4.5 x 4.5" and fits right where the choke cables come out of the fire wall. The vacuum inlet is a direct shot over to the outlet on the manifold. It uses a Jeep 4.0 IAC Here's a perspective shot: Here is a view looking straight on at the firewall. Here's a cutaway shot. You can see the shelf under the needle valves that will allow filtered air into the valves. As the IAC raises it will dump filtered air into the vacuum chamber. The fresh air inlet and shelf area will be done with a core. The vacuum passages will be done as a machine op. Am I missing anything? Derek

Hi Tony Any opinion on how thick the foam should be? I made provisions for a screen at the bottom of the bell and this would give me a filter thickness of 1.25". in hindsight this seems to be a bit thick and may be too restrictive. Thanks Derek

I just finished the Hemi Manifold that was consuming most of my time. I'm hoping to start carving the core molds next week and hopefully the patterns right after that. Scrap is ok if your making mail box parts but anything that requires machining has to be poured from ingot. The amount of inclusions you get in the casting goes way up when your pouring metal with a high scrap content. Tea strainers would work but I'm afraid they would be kind of restrictive. The only thing (in my mind) that the screens are there for is to hold the foam elements in place so I want as much open area as I can get. If I go into production I'll get a price on laser cutting some custom blanks out of stainless.

Independent CNC patternmaker for the foundry industry. This is a pattern for a Desoto Hemi I'm just finishing up Derek

Hi Josh The air filters will be a round disk of perforated metal that sits on a ledge inside the bell, then a chunk of air filter foam that is held in with a domed shaped piece of stainless steel wire cloth like this: The holes are .295 or so. I'm making a set of simple dies to press the screens. Not sure how well this will work but that's where I'm at filter wise for now. Derek

This looks like a winner http://www.eautoworks.com/product-Thermo-Tec-259081.htm Attach this to the bottom of the stainless plate and I'd be good to go. There's enough to do a couple of shields. Derek

I'm basically with Tony on this. I'll make it out of what ever is on the shelf. From a corrosion stand point mirror stainless corrodes less than mill finish. There is less tooth on the mirror for the salts to hang on to. In my thinking mirror is a little to much bling for this application. I think a mill finish would probably be more like what a works team would use. And that's the look I'm going for. One thing I'm going to do is to keyhole the mounting holes so it will be easy to remove. I'm almost done with the Hemi manifold so hopefully I can get something done on the next set of patterns. I finished my CNC conversion of my lathe so I can make my dies for pressing the air cleaner screens. So Much to do! Derek

Thanks Kyle. C'mon it's only 7 pages! If the manifold performs well as in "runs and idles" Then I'll offer them up for sale. The original mantra for this project was: #1 Look Cool #2 Look Really Cool #3 Actually Run So far I think I have 1 and 2 nailed I just need #3 to happen! When I get ready to install them I hope to do a before and after on a Dyno. I will say they won't be cheap though. There's a lot of hand work that goes into these things. Derek

Well I Think I have enough 16GA mirror stainless to make up a heat shield. I's a little harder to work with than aluminum. Does the mirror act as a reflector? Also I really want to do a sandwich of some sort as I don't want to have the insulation visible. Remember "Function follows form" on this project!

I Have some ceramic blanket that I use for the linings in my kilns but it's 2" thick. Mcmaster Carr has this in 1/4" thick: Flexible Silica Insulation Temperature Range: 0° to 2000° F Heat Flow Rate: 0.78 Btu/hr. x in./sq. ft. @ 800° F Density: 10 lbs./cu. ft. Color: White I really don't know how to calculate the amount of heat soak but it's only $13.00 for a 12 x 36" piece so I'll probably give it a try. Derek

Hi Tony I also heard about a Chrysler TPS with an arm on it for attaching to the throttle linkage directly. At this point Ill leave the bosses in place. This will give me plenty of options. Derek

Great news on getting your car back! It would be nice if they had a security forum that we could post to anonymously. Then Info could be shared without any one knowing the geographic location of the poster. Realistically the internet is full of great ideas for security measures. All I'll say about mine is I don't have an ignition lock cylinder in my car at all and I sleep very well at night. I have multiple systems that can be engaged depending on the location and level of security I want. Of course a flatbed or a gun changes all of that! If someone really wants your car their going to get it. Derek

Thanks Phar I have bosses (the gray ones)on the bottom of the manifolds for mounting a heat shield. I'm thinking along the lines of a sandwich of aluminum and ceramic insulation. Maybe a ceramic coated piece of aluminum would be enough. Derek

Kevin from Extrudabody was kind enough to send me a 3D file of their TPS switch. I have it mounted on the bottom of #6 tube. The only thing you can see from the top is the plug so It won't be too bad. Thanks for the reminder on this Phar. I totaly would have forgotten to put the bosses in place. I'm pretty sure I'm going to cast a vacuum log as well. This will be machined to accept a Jeep 4.0 IAC and a bleeder arrangement for the main idle setting. It will have a small air cleaner for the intake air. This will mount on the firewall near the booster. This way I can have a single hose leading over to the manifold and it keeps the clutter kind of hidden. Anyone see any problems with this? Thanks Derek

Thanks! You can see a ridge just at the inner end of the bell. A mesh screen will sit on the ledge. Then a piece of foam air cleaner will go in the end of the bell with a domed mesh screen on the outside holding it in. Derek

Hi Phar I plan on using one from extrudabody http://www.extrudabody.biz/servlet/the-126/TPS-dsh-1008/Detail It will mount under one of the throttle shafts, Probably the rear one. Thanks for the reminder I needed to order one so I can put the bosses on the pattern. Derek

Thanks Scott Also I wasn't trying to shut you down. If you have Ideas throw them out there. That's what this things all about. Derek

Now PalmettoZ if you had carefully read all 6 pages of this thread you would have read the post where I proposed this very thing! Thanks for the suggestion and offer. That's exactly how I'm going to do it. I'm going to cut the blanks out on the mill and then true them up on the lathe. Derek