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Billet Alu Engine Mount Bracket

 
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Mike9311  



Joined: 14 Dec 2004
Posts: 639
Location: Chicago-ish

PostPosted: Mon Apr 10, 2017 6:53 am    Post subject: Billet Alu Engine Mount Bracket Reply with quote

So I already spilled the beans with some posts in the 'doing anything exciting' thread but I'll bring it all together here.

I went from scan, to CAD, to FEA, to CAM, and now machining. There was a setback at the machine, a big one in fact but its back on track

Anyway, the video is another playing-it-safe routine, since its the first one. I will lower the safety clearances and up the speed and feeds once sorted. There is a lot of time savings yet to be had especially during roughing

Enjoy...

Scans



Very start of the CAD overlaid on Scan. Its sloppy but its a start and I was anxious



Skipping ahead to when I quit trying to skim off weight because I need it on a car. Spring seems like its here and there is an intercooler needing testing Its overkill but the law of diminishing returns was in play





Jumping over the CAM process straight to the machining with a VIDEO

https://vimeo.com/212484931

Next step now in the CAM on my laptop and then back on the machine tomorrow if I get some time. Right now I can actually remove the part from the vice and it relocates to within 0.0004" of an inch

Next step in CAM



I'll upload some billet pics later...my little ones just ran off with my phone
_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
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Mike9311  



Joined: 14 Dec 2004
Posts: 639
Location: Chicago-ish

PostPosted: Mon Apr 10, 2017 7:26 am    Post subject: Reply with quote

Phone back in my possession. As promised




_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
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Fasteddie313  



Joined: 29 Sep 2013
Posts: 1432
Location: Not Detriot - NMI

PostPosted: Mon Apr 10, 2017 7:45 am    Post subject: Reply with quote

Wow, very nice
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1980 931S LSD FMIC hobby - 01 RS25 coupe - 95 M3 coupe - 06 X5
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Mike9311  



Joined: 14 Dec 2004
Posts: 639
Location: Chicago-ish

PostPosted: Mon Apr 10, 2017 9:00 am    Post subject: Reply with quote

Thanks! I'll have more soon
_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
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morghen  



Joined: 21 Jan 2005
Posts: 7716
Location: Romania

PostPosted: Mon Apr 10, 2017 5:17 pm    Post subject: Reply with quote

pretty damn cool!
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Mike9311  



Joined: 14 Dec 2004
Posts: 639
Location: Chicago-ish

PostPosted: Thu Apr 13, 2017 11:49 pm    Post subject: Reply with quote

Another progress pic. Going to thread the 3 bolt flange holes just so I can fixture for the next step. Thats why they are smaller. Funny how they look like they are in the wrong position but its actually because its an exact copy of the original part


_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
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Mike9311  



Joined: 14 Dec 2004
Posts: 639
Location: Chicago-ish

PostPosted: Wed Apr 19, 2017 8:57 am    Post subject: Reply with quote

Done other than cleaning up and Anodizing (...and drilling mounting holes larger)

750g Alu vs 2Kg Stock iron (roughly 1.7lbs vs 4.4lbs)








_________________
1980 931 ...off with the cobwebs
1982 931 Entwicklungsfahrzeug
1979 924 NA M471/M481 / ohne M650 Herausnehmbares Dach
0.5 1982 931 smashed parts car
1982 931 parts car?
1980 924 NA (R&D lightweight)
1982 931 WB wana-be GTR race car
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View user's profile Send private message
Dutch924-racer  



Joined: 23 Jul 2007
Posts: 977
Location: The Netherlands

PostPosted: Wed Apr 19, 2017 5:11 pm    Post subject: Reply with quote

very nice!
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937 trackday car
Series 2 engine
951S turbo and intercooler
937 DITC
Fast road camshaft
Forge recirculation valve + boost controller
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morghen  



Joined: 21 Jan 2005
Posts: 7716
Location: Romania

PostPosted: Wed Apr 19, 2017 6:37 pm    Post subject: Reply with quote

Dutch924-racer wrote:
very nice!


+1
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