Datsun B310 turbo coupe, A15 project

[datzenmike]

You finish the oil pump???

[Atomic]

11 hours ago, datzenmike said:

You finish the oil pump???

If I had the time, almost in a middle of a burnout

[datzenmike]

Understood.

[Atomic]

I'll be having 3 weeks holiday soon, hopefully I can machine some Datsun parts and drop the engine in the engine bay again!

 

Painted some more parts during the weekend:

[Atomic]

Finally on holiday, feels good!

 

Bought some cork gasket and made new oil pan seals:

 

Also wondered if the oil thrower disc is necessary? I hear that oil might leak from the front seal if the seal is worn or something. The problem was that I couldn't find the thrower disc anywhere, even the other donor motor didn't have one?

 

Anyways assembled some screws on:

The other question that bothered me is that what sealant should be used with paper gaskets? I have heard that some use grease to make them easy to peel off later on and the gasket material itself seals, no need for silicone sealant? 

 

Painted the water inlet and also the crank case breather line:

Which now has AN fitting:

 

And had some time between paint layers so I decided to paint the engine numbers:

[Atomic]

Got the holders finally in right size:

 

Made the oil pump spacer, will do a 3D SLA print to try out how it fits before machining one out of aluminum:

 

Also planning to do multiple intake flanges (also for sale):

[Atomic]

Machining time!

 

I ran to an error first because the block size in the CNC control was limited to 9999 blocks, and I had to go through 99999 blocks. So:

I fixed that with some piece of code that resets the counter everytime it reatches 9999 blocks, it starts again from 0...1...2...3.. etc. After that was fixed, everything went smoothly:

 

Except when I had some errands to run... So I stopped the machine and calculated that I was somewhere around 58k blocks down the line... But of course that block would be 8k something as the resetting counter... So I tried to delete the all other 8k blocks and start the program then from the ''58k'' block, but it didn't work... So I had to delete all the code until 58k block and modify the starting counter and then it was easy to continue:

 

So first batch is ready, 2 pairs are already reserved. One pair from this batch is for sale. Send me a DM and I can customize the oval hole size suited for your application.

 

I'm also making oval to round port adapters in next batch:

 

So they are easier to weld on.

 

Pricing:

80 euros per pair w/o adapters

125 euros per pair with adapters

 

I will also machine the oil pump flanges, so hmu in DMs if you're interested in any.

 

 

 

 

[Atomic]

Milled more, got the first pair ready, I'm going to use the first pair to myself with weld on adapters, so the oval holes are bit bigger:

 

Then I'm going to make a Jig from leftovers to house in the intake funnels that transition from oval to round, the jig will be used to machine the transition (see radiuses):

 

[Atomic]

First set of flanges done:

 

Clean table for adapters that I'm starting off tomorrow

[Atomic]

Adapters incoming:

'

 

And started to make the jig where I can do the finishing transitions between oval and round:

 

 

 

 

 

 

[Lockleaf]

Very nice looking work.

[Atomic]

Tightened the oilpan:

Started lifting the motor back in:

 

The transmission was pain in the ass to haul in by myself, took some heavy lifting before I could insert the jack underneath:

I was able to use the DIN 912 M10 bolts now as I threaded the transmission side

[Atomic]

Soon all of the adapter blocks are ready! I figured finally the problem with the post processor and linearized arcs. So now I can run 100% feed speeds:

 

After these are done, I'm starting with the oil pump adapters!

[Atomic]

All adapters are ready:

Made the CAM profile for the oil pump spacer:

 

I bought 4.6 mm drill head and some countersunk tooling for the pin locations (notice the CAM picture with undrilled holes still). So I'm still waiting for those to arrive later this week. If the fitment is good (perfect) I will run multiple spacers for sale

 

 

Edited November 3, 2020 by Atomic

[Atomic]

Oil pump spacers almost done, I just need to make a re run since the zeroing out changed somehow and thus the locating pins are in completely different spot??

(sorry for leaving some chips still into some of the holes, looks nasty against the backlight)

Seems like Y-axis was giving some mumbo jumbo. But next time it will be easy to do in one sitting as the whole program just takes 20 minutes to run anyways...

 

[Mattndew76]

Looks like you are getting a lot of recut in the holes.

[Atomic]

3 hours ago, Mattndew76 said:

Looks like you are getting a lot of recut in the holes.

recut? All holes are clean, its just the chips that are hanging to the part as it was still sticky from the cutting fluids. Maybe I should air blast parts before showing anything 😄 

[Mattndew76]

Recut causes a galling effect on the perpendicular surfaces. Your endmills are re-cutting the borings along the axial motions. It will wear down and chip your carbide over time. Run a narrower stream of coolant (cutting fluid) with a bit more pressure to evacuate the chips, or program the chip clearing into your cut pattern so the metal chips evacuate in a single direction. 

 

Good work for a new guy to CNC though.

Edited November 21, 2020 by Mattndew76

[Skib]

This thing is bad ass 😎 love it

[slowlearner]

Hey @Atomic how is it all going? Keen for an update. 🙂 

[Atomic]

@slowlearnerOh shit it has been a while.

 

I'll be having a holiday starting in 1 week so that's when I will start to make the intake manifold V2.

 

Got the oil pump spacer almost all holes dialed in, tolerances just right for whole assembly to turn. Got myself a lathe now too and bought another CNC machine. Waiting for little more money to come in to buy a kiln.

[slowlearner]

7 hours ago, Atomic said:

@slowlearnerOh shit it has been a while.

 

I'll be having a holiday starting in 1 week so that's when I will start to make the intake manifold V2.

 

Got the oil pump spacer almost all holes dialed in, tolerances just right for whole assembly to turn. Got myself a lathe now too and bought another CNC machine. Waiting for little more money to come in to buy a kiln.

 

Great to hear from you. 🙂

 

Another CNC! Wow! 🤓 🍿

[Atomic]

Starting to piece the intake manifold together:

Made some 3D printed jigs:






And after cleaning some horrible welds as it took some time again to get know how to handle aluminum, oof:

 

 

[slowlearner]

That looks better than my efforts with JB weld, so don't stress. 😆

[Atomic]

Did a 3D printout from the ''old'' ''new'' manifold design to just see how it fits over the valve cover etc. It measures 5 mm lower than the old one so I should be fine with the hood clearance plus able to get the valve cap open, huzzah!

And then I'm just doodling the new intake manifold in CAD, o-ring sealings on mating surfaces:

And thread M6 inserts implemented for the pockets: