SKULD 666

[racket]

Hi Mark

Yep , a nice finish on the castings , Andrew said they're cast in a better machining material than last time when we cast the 10/98 comp housings .

LOL ...........I still don't know how I'm going to hold the bits on the face plate to square up that first face that I can then grab in the chuck, but I guess I'll work out something , might have to grind a bit more out of the lathe bed for clearance on the fasteners :-(

Cheers
John

[racket]

Hi Anders

Yep , they'll do the job nicely , lotsa machining ahead to make some shiny surfaces :-)

Cheers
John

[gidge348]

Beautiful job John, what material did you have it cast in?

Regards
Ian...

[racket]

Hi Ian

Andrew tells me its a strontium based alloy used by some of the auto manufacturers for transmission housings , it has a nice "ring" to it when flicked with the finger.

Cheers
John

[racket]

Hi Guys

Well I finally started turning metal after an 18 month break , it was nice to smell the cutting fluid fumes again



The front comp cover is pretty big and required some lateral thinking to get it secured on my 14.5" dia face plate



Requiring a half hours use of the side grinder to make some clearance in the lathe bed



That black cast iron dust goes everywhere , still pickin' it out of my nose ;-)



Probably another days work to finish the internal profiling of the cover, getting that compressor "curve" just right is going to be a problem as I can't fit it to the cover whilst the cover is in the chuck , the comp wheels snout is too long .

Cheers
John

[Johansson]

Hi John,

Very clever way of fitting the large housing to the lathe chuck! I never realized just how huge the housing was before I saw the mug next to it.

Keep up the good work my friend!
/Anders

[racket]

Hi Anders

LOL.............the cover is bloody huge , its stretching my machining abilities to the limit ,its kinda scary machining this thing as its hard to hold , don't won't it flying out of the chuck when I do something stupid , ....... thankfully the diffuser is a tad smaller and can be mounted a bit easier , but will still need the "special" extra long tool holders to machine it.

I have noticed that the "shrinkage" factor between pattern and casting doesn't seem to be quite as great with this material as the finished OD of the cover is ~5mm larger than expected , but thats measuring it with my builders steel tape , I don't have a large enough vernier to do the job , my 200mm vernier only just copes with the comp cover snout OD , and my 12 inch vernier is good for nothing on this job , might have to cobble something together so that I get the diffuser and front cover the same size , or wait and machine both ODs once they're bolted together .

Cheers
John

[pitciblackscotland]

Hi John,
Ah so that's how we have to clap down the comp cover nice Are you using 3/8 hex bolts . Yeah that is scary machining that cover lol you know i will make somthing more heavy duty . My thinking is welding 6x 1 inch rod and tap 1/2 inch threaded holes that should hold the comp cover down .

Cheers,
Mark..

[racket]

Hi Mark

Yep, 3 puny 3/8" UNF bolts , I did use high tensile ones though ;-) .............had to make it as compact as possible to limit the lathe bed grinding,..... worked OK .

I've been doing a bit more machining of the internal "corner" where the air gets turned towards the flametube, took me a few hours to find the necessary parts and get organised for a half hours turning . ..............will post some pics of the process later .

Cheers
John

[turbochris]

when you get it running don't put your fingers near the intake

[racket]

Hi Chris

LOL, those titanium blades wouldn't have any trouble making mince meat outa them, bones and all :-)

Cheers
John

[racket]

Hi Mark

A few pics of the setup used to machine the "corner"





the pivoting tool cuts a nice ~22mm radius , to adjust the radius diameter just move the cutting edge in or out of its hole and tighten the grub screw locking it in place.





Currently working on the inducer curve , its gotta be done by hand , lotsa sand paper .

Cheers
John

[pitciblackscotland]

Hi John,
Very good i have a cutting tool that might be good to use for machining the corner . I'll post a pic of it tomorrow, is that large pulley you are using to damping the vibrations .

Cheers,
Mark.

[racket]

Hi Mark

LOL,..........no special reasons , the pully allows me to put some force on the cover to stop it flying out of the chuck if I stuff up and a tooling tip digs in , the cover is only held internally in the snout by ~8mm of chuck jaw, I don't have any external jaws for my chuck and as the cover's snout is 200mm in the OD, I can't hold it externally with the jaws I have :-(

Cheers
John

[pitciblackscotland]

Hi John,
Ok got this cutting tool which i think i can use just need to weld a steel rod onto the rotating part.

Cheers,
Mark