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CNC A series Oval Flange
No life (a.k.a. DattoMaster)
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G'day all,

I think I'm pretty happy with my flange design so I think it's time to share. There's a few views to give an idea of what it looks like.

Design features:
-Symmetric
-Houses Bosch style injector with the pintle cap removed, the counter bore can be adjusted for different styles
-1-1/2" pipe fits into the flange, it's intended to be snug so it can be positioned and then welded
-Locates off the two top studs, I've had a guess but without the original head drawings's I can't evaluate tolerance stack up but I figure it can be drilled out if it's too tight.
-Thread between injectors for fixing fuel rail
-Smooth transition from oval port to round

I'm hoping to find a machinist interested in collaborating since this is the only part of my new manifold I can't make myself. I can generate a parasolid really quickly, if I need to draft it up it'll take a bit longer. It would be best to make one first (which I'd fit to my car) and once the design's solid we could make up some more for anyone else who's interested. I'm based in Adelaide now so someone around here would be awesome! All I really want to get out of the adventure is the manifold I've designed out my head and on the car.

Cheers,

Dylan

Attach file:



jpg  A15 mani view 1.jpg (53.54 KB)
11744_5733058d80897.jpg 751X403 px

jpg  A15 mani view 2.jpg (62.49 KB)
11744_5733059a5ca1f.jpg 775X407 px

jpg  A15 mani view 3.jpg (52.32 KB)
11744_573305a56cb84.jpg 633X445 px

jpg  A15 mani view 4.jpg (52.07 KB)
11744_573305acccf84.jpg 669X482 px

Posted on: 2016/5/11 11:25
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Re: CNC A series Oval Flange
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If you used the measurements that we discussed earlier then the location should be pretty close. The first set that I made were drilled to 8.3mm and they slipped right on.

Posted on: 2016/5/11 13:30
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Re: CNC A series Oval Flange
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Daq I would help you out with some CNC work if we were on the same side of the world.

Posted on: 2016/5/11 17:35
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Re: CNC A series Oval Flange
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This may be stupid of me to ask, but are the manifold flange for A15 and A12 the same ?
The the only difference port size? Or is spacing ect different?

Posted on: 2016/5/11 20:49
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Re: CNC A series Oval Flange
No life (a.k.a. DattoMaster)
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Engine Room: I did most of modelling these last year/ early this year and have not gone back to check your measurements against what I used, the 3D printed one I made 2-3 months ago fitted alright (the holes usually print undersize due to shrinkage). I'll go back and check this later. The last few months have been hectic to say the least.

Matt: If no one else jumps in lets just do a trans-pacific collaboration, it'll be a bit slower and more expensive but no reason it can't work.

Theo: The flange changes by head oval or round port and the position of the studs. I think there's a write up in the tech wiki, I don't remember off the top of my head. I have a H89 head on my engine, I could probably do the others once I know that this one works.

Posted on: 2016/5/11 23:34
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Re: CNC A series Oval Flange
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It's okay Dylan. Don't sweat it
I'm making me a set on my own. I have 2 design that I have been working on these last weeks since the recent post about manifold flange came up.
I am making a set that are of std. oval design, but my head is round so slight port work needs to be done to match port.
Other set I'm working on is a porting set, that have a D shaped intake, and enlarged exhaust. This one will have to be heavy portet, and have the water jacket above the intakes blocked or filled.

Posted on: 2016/5/12 20:02
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Re: CNC A series Oval Flange
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Quote:
are the manifold flange for A15 and A12 the same ?
The the only difference port size? Or is spacing ect different?

A12: Round port or Large-oval port
A15: Round port, Oval port, or Small-oval port

Spacing is exactly the same, and they are symmetrical (left/right is same)

Two different bolt patterns (top row of bolts differs)
* Early: 1966-1980
* Late: 1973-2010
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Posted on: 2016/5/13 8:01
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Re: CNC A series Oval Flange
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Render of what I have been working on for the A12 I have
(Sorry for the thread steal)

Open in new window

Posted on: 2016/5/15 15:37
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Re: CNC A series Oval Flange
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Quote:

tboe0 wrote:
Render of what I have been working on for the A12 I have
(Sorry for the thread steal)

Open in new window

Posted on: 2016/5/15 22:12
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Re: CNC A series Oval Flange
No life (a.k.a. DattoMaster)
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Nice!

Posted on: 2016/5/15 23:27
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