Help - AAN - ABY - ADU exhaust flange design

[AndyP]

Try this place for castings:-

http://www.taylorsfoundry.co.uk/

They did a job for me at work and they were very reasonable on price, nice quality too, good enough to get past an MOD inspector.

[aspro]

Here is the Audi Flange for you!

http://www.file-upload.net/download-...lange.DXF.html

Are you Designing that Manifold for a Diesel?

Good Luck...

thanks lupo:

fits like a glove BTW

[Billman]

Make it for 500+ on reasonable price. I am sure you can find good manufacturers in Englang or in the East with good prices.

[Billman]

Hi Billman you are right the price to cast and pattern make in this country would be v expensive.

What i am trying to acheive is a solid british design that can be produced elsewhere. in 2 sizes 1 as standard and 1 to RS2 and above spec.

also looking at pressing the main part in two halves see image - maybe inconel

Does anyone have a DWG or DXF of the flange for an ABY / AAN.

Is it possible to cast inconel or press it from inconel "sheets" and then weld it? Take care of the runner design and collector.

[aspro]

Hi Billman

The inconel version would be pressed in 2 halves then welded together.

The Cast version would be cast from ferrous - just trying to get some material specs together.

[Animal Mother]

Ever thought about a cast ceramic manifold?

[aspro]

mmm cast ceramic would be nice wouldn't it but i have no knowledge of the process or material.

Does anyone have access to any rapid prototyping kit. Would be nice to get a prototype done cheaply. At the moment these costs are comming in at around £900.00 for one.

Anyone who wants get involved in this process is more than welcome:

My goals are to design a good flowing manifold RS2 spec or better that can at least be cast from ferrous for longevity and retail for no more than £400.

I need help with
rapid Prototyping.
Flow Analysis.
Pattern Making.

If anyone wants to use any of my SW files they are more than welcome.

[aspro]

here are the current drawings as pdf

[Lupo911]

mmm cast ceramic would be nice wouldn't it but i have no knowledge of the process or material.

Does anyone have access to any rapid prototyping kit. Would be nice to get a prototype done cheaply. At the moment these costs are comming in at around £900.00 for one.

Anyone who wants get involved in this process is more than welcome:

My goals are to design a good flowing manifold RS2 spec or better that can at least be cast from ferrous for longevity and retail for no more than £400.

I need help with
rapid Prototyping.
Flow Analysis.
Pattern Making.

If anyone wants to use any of my SW files they are more than welcome.

I can Help you

I do have a Stratasys Printer here in my Shop. Send me your File as a STL, and i can give you a Quote.

[aspro]

Hi LUPO

That would be great thanks - what is your email. Also please can you elaborate on your diesel comment earlier would be interested in any advice you may have ?

[Billman]

It looks like a log design. Should go for a design looking more like a header than log.

[aspro]

here is the latest

[Billman]

it seems very flat at the collector. Orientate yourself to the RS2 design but improove its flaws (meaning same diameter all the way and a header manifold type collector).

[Bram]

Have you checked the design of the 034 EM that they took out of the shop? That seemed to be flowing enough, but the material (SS) was just not strong enough

[aspro]

Hi Bill

that picture is not a great representation of what is going on:

although it is fundamentaly a log design i have made efforts to increase the diameter as runner 1 runs into runner 2 same for runner 5 running into runner 4.

i will try a post some sectional info laters

basically the suface area of the section of the log between cylinder 2 and the collector or cylinder 4 and the collecter is 2* the surface area of an exhaust port.