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Thread: Forced Induction Section Fabrication Thread

  1. #1701
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    Looking good dude! Youve made quick progress


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  2. #1702
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    Not super pretty, and I didn't have any dimensions to go from (and didn't bother with a picture lol), but I made this for my wife this afternoon. It's a mount that's used for a TRX fitness system:

    TRX mount by Jon Kensy, on Flickr

    TRX mount by Jon Kensy, on Flickr

    TRX mount by Jon Kensy, on Flickr

    TRX mount by Jon Kensy, on Flickr

    I made my center hole a little large for the plasma circle cutter, so I got a couple steps in the diameter while cutting, but meh, not critical. Minimal dross. I can't complain for a hand cut circle out of 1/4". 3/8" rod bent free hand. Was going to swap to the small torch and 360 weld the rods but then realized I already overkilled it.

    The manufactured part is $40 - $45 and made of like sheet metal... nah thanks. Next up is some powder coating once she lets me know the color!

  3. #1703
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    Quote Originally Posted by vollosso View Post
    Looking good dude! Youve made quick progress
    Thanks man, yeah my retirement plans are progressing well.

    Quote Originally Posted by 5mall5nail5 View Post
    I made my center hole a little large for the plasma circle cutter, so I got a couple steps in the diameter while cutting, but meh, not critical. Minimal dross. I can't complain for a hand cut circle out of 1/4". 3/8" rod bent free hand. Was going to swap to the small torch and 360 weld the rods but then realized I already overkilled it.
    I'm definitely getting a 625 this year. I need a proper compressor first but the thick stainless work has made me miss my plasma cutter. It was just an ebay china one but it got the job done and would have saved me several effed up carbide blades.

  4. #1704
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    Quote Originally Posted by TheJuggernaut View Post
    I'm definitely getting a 625 this year. I need a proper compressor first but the thick stainless work has made me miss my plasma cutter. It was just an ebay china one but it got the job done and would have saved me several effed up carbide blades.
    Yeah the 625 is a serious machine for the money. It ripped through this 1/4" 1018 with no issues - well, except for my steadiness. I deliberated for a while gouging or piercing to start the circle and then said screw it and just started the hole attachment with the drag tip - not even a flinch.

  5. #1705
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    Cool as always jon.

    I could definitely do fabrication as a retirement plan hah.


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  6. #1706
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    Quote Originally Posted by PEI330Ci View Post
    What design limitation of the OEM spindles did you find?

    Not an argumentative question, just pure curiosity.
    One huge advantage is you can drop the mounting points for the LCA and tie rods 20mm to help correct the poor roll center location and bump steer while lowered.

    Also you could make a spindle out of steel with some nice pocketing and reduce the excess. Lower weight and more strength for threads to bite into and not a brittle material. Aluminum suddenly snaps....steel bends making failures much less severe. Just food for thought!
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  7. #1707
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    Quote Originally Posted by wazzu70 View Post
    One huge advantage is you can drop the mounting points for the LCA and tie rods 20mm to help correct the poor roll center location and bump steer while lowered.

    Also you could make a spindle out of steel with some nice pocketing and reduce the excess. Lower weight and more strength for threads to bite into and not a brittle material. Aluminum suddenly snaps....steel bends making failures much less severe. Just food for thought!
    I like you're thinking. I was of the same mind. But could we not just raise the bearing mount/spindle to take care of the geometry? I am currently using the SLR Speed Roll center correction kit which provides about 28mm of roll center and bump steer correction. It also does a nice job of speeding up the steering a bunch, and I boosted that some more with a Z3 steering rack!!

  8. #1708
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    Raising the spindle is the same thing assuming the strut tube connection moves up the same amount. If you just move the spindle without the strut mount then i don't think you get the gains in roll center correction. Its been a long time since I did any RC calcs
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  9. #1709
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    Started the manifold. Flange done, started measuring the runners



    Also did some more work on the expansion tank. Mounted the catch can. Just need the connecting line, and to add the pneumatic 90's with the clear tube to show if there's anything in the catch


  10. #1710
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    Quote Originally Posted by TheJuggernaut View Post
    Started the manifold. Flange done, started measuring the runners

    Also did some more work on the expansion tank. Mounted the catch can. Just need the connecting line, and to add the pneumatic 90's with the clear tube to show if there's anything in the catch
    Solid work!

    These make me want to buy a TIG (even more...)

    - - - Updated - - -

    Quote Originally Posted by 5mall5nail5 View Post
    Not super pretty, and I didn't have any dimensions to go from (and didn't bother with a picture lol), but I made this for my wife this afternoon. It's a mount that's used for a TRX fitness system:

    I made my center hole a little large for the plasma circle cutter, so I got a couple steps in the diameter while cutting, but meh, not critical. Minimal dross. I can't complain for a hand cut circle out of 1/4". 3/8" rod bent free hand. Was going to swap to the small torch and 360 weld the rods but then realized I already overkilled it.

    The manufactured part is $40 - $45 and made of like sheet metal... nah thanks. Next up is some powder coating once she lets me know the color!
    Drooling over tools:

    Drill press with coolant feed

    Plasma

    TIG

    - - - Updated - - -
    Last edited by PEI330Ci; 04-23-2017 at 11:35 PM.

  11. #1711
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    Jug, how much was all the manifold bits?
    '97 M3, Estoril blue, 2 dr, euro 6-spd, EFR 9180 divided T4 .92 IWG, RK tuning, CP 8.5:1 pistons, Eagle rods, Schrick cams, L19 11 mm ARP studs, O-ringed block, Supertech stainless/inconel valves, Supertech springs & Ti retainers, ported head, S54 oil pump/pan, 80 lb. injectors, OBD1 intake manifold, Steedspeed twin scroll T4, 3.5" SS exhaust, eBoost2 EBC, HFS-4 W/M injection, AEM Failsafe, Zeitronix data logger, Racelogic TC, OpenOBC w. ethanol %, Ireland Eng. engine mounts, UUC black tranny mounts w. enforcers, UUC twin disc feramic, ARC-8's, MCS 2-ways, Z3 rack, Rallyroad strut bar, X brace, Eibach sway bars, Ground Control LCAB bushings, Bimmerworld RTAB's, Powerflex subframe bushings, 210 4-clutch LSD, Stoptech BBK, titainium shims, steel braided lines, brake cooling ducts.

  12. #1712
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    Quote Originally Posted by chikinhed View Post
    Jug, how much was all the manifold bits?
    The equivalent of 700 US shipped to Canadia

  13. #1713
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    Did it come with the TB & TB flange?
    Last edited by chikinhed; 04-23-2017 at 11:48 PM.
    '97 M3, Estoril blue, 2 dr, euro 6-spd, EFR 9180 divided T4 .92 IWG, RK tuning, CP 8.5:1 pistons, Eagle rods, Schrick cams, L19 11 mm ARP studs, O-ringed block, Supertech stainless/inconel valves, Supertech springs & Ti retainers, ported head, S54 oil pump/pan, 80 lb. injectors, OBD1 intake manifold, Steedspeed twin scroll T4, 3.5" SS exhaust, eBoost2 EBC, HFS-4 W/M injection, AEM Failsafe, Zeitronix data logger, Racelogic TC, OpenOBC w. ethanol %, Ireland Eng. engine mounts, UUC black tranny mounts w. enforcers, UUC twin disc feramic, ARC-8's, MCS 2-ways, Z3 rack, Rallyroad strut bar, X brace, Eibach sway bars, Ground Control LCAB bushings, Bimmerworld RTAB's, Powerflex subframe bushings, 210 4-clutch LSD, Stoptech BBK, titainium shims, steel braided lines, brake cooling ducts.

  14. #1714
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    Quote Originally Posted by chikinhed View Post
    Did it come with the TB & flange?
    No, that's one of the reasons I am doing this, I get to do it my way. I'm using a K-Tuned 90mm TB Mustang 5.0 fitment. Made right here in the GTA, really nice piece.

    But PPF has everything you'd need to finish it, incl TBs, fuel rails etc.

  15. #1715
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    Nice work Mr. Juggernaut! Excited to see how this works out.
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  16. #1716
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    I should probably update my thread at some point but for now there's so much I have done and have to do I'll just keep sharing some of the fab stuff.

    Finished the motor mounts, moving the engine back 0.3" to give the drysump mandrel a little breathing room.






    The oil pan is for an E36 so even being low profile, it didn't clear the crossmember and the steering rack had to be moved forward, but all good now.




    Before the engine can go in I need to make the intake up to the plenum to take advantage of the convenience. The only hard part with the PPF kit is that the billet flange is oval while the bends are generic round tubing. I thought about it and made a crushing jig out of a large round pipe. Tried it on a piece of scrap and it worked so well I made one runner. Looks like I'm in business, 5 more then I can stick it all together. Ended here as I was getting tired and wanted to end on a high






  17. #1717
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    Niiice.

    I have a similar jig for exhaust work


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  18. #1718
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    I could build a nice table but this is really tempting.... Besides after time and materials I feel like you could get close to that price trying to reproduce something with all of the options. Some have been sold in the $900 range I'm told.



    https://store.snapon.com/MIG-Welders...k-P818845.aspx Plus there's room for 2 tanks so I can get a personal MIG later and have it all in one place.
    Last edited by somebody5788; 04-30-2017 at 10:00 PM.
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  19. #1719
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    Quote Originally Posted by somebody5788 View Post
    I could build a nice table but this is really tempting.... Besides after time and materials I feel like you could get close to that price trying to reproduce something with all of the options. Some have been sold in the $900 range I'm told.



    https://store.snapon.com/MIG-Welders...k-P818845.aspx Plus there's room for 2 tanks so I can get a personal MIG later and have it all in one place.
    I built a large table with 2x2 square and 1/4" plate for like (iirc)240$ and 3-4 hours.


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  20. #1720
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    When we moved to our current (final...?) location, I wanted nice, fast/easy and not overly expensive; five (5) years ago, I bought one of these for around $1k. Looks like the list price is about double that now, but I'm sure you can shop around for online bargains (relatively speaking).

    I have my Miller Dynasty 200DX & Spectrum 625 (older/larger than the same 625 of today) and Argon bottle on it. The MIG (Millermatic 252) & bottle are on their own (built in) rig, and the spot-welder is also stand-alone.

    The welding shield is still in the box, since I work alone. I did buy a second set of casters though, since I didn't want it to sag in the middle, and I';m not about to run the adjusters down to the floor every time I move it.


  21. #1721
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    The flange part is done, next just need to mount the fuel rail then wait until the engine's in the car to figure out the plenum dimensions.


  22. #1722
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    Dont you love aluminum? No back purging!


    Sent from my iPhone using Tapatalk
    1989 535i - sold
    1999 M3 Tiag/Dove - sold
    1998 M3 Turbo Arctic/black - current
    2004 Built motor TiAg/Black - Sold
    2008 E61 19T Turbo-Wagon - current
    2011 E82 135i - S85 Swap - current
    1998 M3 Cosmos S54 swapped Sedan - current

    1998 Turbo: PTE6870 | 1.15 ar | Hp Cover, Custom Divided T4 bottom-mount, 3.5" SS exhaust, Dual Turbosmart Compgates, Turbosmart Raceport BOV, 3.5" Treadstone Intercooler, 3.5" Vibrant resonator and muffler, Arp 2k Headstuds | Arp 2k Main studs | 87mm Je pistons | Eagle rods | 9.2:1 static compression, Ces 87mm cutring, Custom solid rear subframe bushings, Akg 85d diff bushings, 4 clutch 3.15 diff, , Poly engine mounts, UUC trans mounts W/ enforcers, 22RPD OBD2 Stock ECU id1700 E85 tune, 22RPD Big power Transmission swap w/ GS6-53

  23. #1723
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    Yeah but it's "pleasant" in its own way

  24. #1724
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    Looks nice juggernaut!
    -Nick
    91 E30 M42 on VEMS

    Turbo Camshaft Thread

  25. #1725
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