Supercharging An Mx5 Engine

[richardm6994]

Tonight's been boring......

 

 

 

 

[Shaft]

Mmmhhh.... CCMT boring bar.

[richardm6994]

More boring....58.5mm dia x 105mm deep hole with a 64.5mm x 5mm shoulder complete

 

Then 35mm chopped off the opposite end....this really was boring!!!

 

So back to machining.....this little game is called 'don't crash the traverser into the ali'.....because of the size and offset in the chuck, I've had to machine this in 2 stages.

 

 

Still along way to go...7 hours so far on this lump

Edited October 9, 2014 by steamer

[Shaft]

Told you to arch it in the 4 jaw!

Ner, Ner.

[richardm6994]

I can't do what we spoke about because of a couple of reasons.

What I'm turning here is the bypass end.....it's coming down to 50mm dia x 80mm long with a 10mm thick x 70mm dia flange at the end

[Shaft]

Aaahh.... I'd assumed from the photo you where arching the top prior to turning the spigot.

[Bob Tucker]

I can't tell you guys just how much I admire the skills (& machinery!)

you can call on to turn a lump of metal into a thing of beauty.

I cant even work out how you can cut a half circle into a square block

leaving the other half square.....looks just like magic to me.....

Ive got a hacksaw & a blunt file....& I cant use either of them properly

[Shaft]

Look at the chuck jaws on the lathe Bob.

It's a 4 jaw chuck and all 4 are independent of each other. This allows off Centre turning. The Centre of the Dia Rich is turning is the centre of the spindle.

Optical illusion mate.

[richardm6994]

This should give an idea of what the finished article will look like.

 

The spout at the rear is for the bypass valve to bolt onto and the outlet spigot will be machined out of amother price of aluminium and bolted on simply because the chuck jaws on my 4-jaw arnt big enough to machine both ends from the solid lump.

 

[Guest mower man]

My little lathe hasa 4 jaw independant chuck,it wouldn't handle any thing that big and I certainly have not got the skills to do it I'll carry on making pins and bushes[badly].If you go to the Harris v8 site you can watch a big cube of alloy being made into a crank case and block for their bike based 2.8 40 valve engine ,its incredible mower man

[Bob Tucker]

Still looks like magic to me.....

I can't build stuff like that, but I do design stuff.....

Ray needed a "top hat" for his new inlet to handle the air from 2 88mm Holset turbos

and accept a 102mm throttle body. There's nothing available off the shelf.

So I drew up a number of designs, knocked up prototypes in balsa wood, measured

cross sections & volume & used fluid dynamic formulae to make sure there are no pressure drops.

Here's the result....

 

The big alloy can is an ice water intercooler. I just wish we'd started with a bigger car

Edited October 10, 2014 by Bob Tucker

[richardm6994]

And after another 7 hours machining;

 

 

 

 

 

 

 

 

 

 

The bypass valve flange will be shaped by hand to match the bypass valve.

 

 

[Shaft]

You'll be able to lift the engine out with that flange!

Edited October 11, 2014 by Shaft

[richardm6994]

It's going to have m6 threads in it so needed the thickess (8mm thick)

[richardm6994]

Another 2.5 hours......

 

 

 

 

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