I'm back with a new PVC intake

[Dusterdude]

I like that

Sent from my LG-D850 using Tapatalk

 

[dan filipi]

Clean cuts, what did you use?

 

[chuck c]

dan filipi » Thu Mar 24, 2016 7:24 pm[/url]":f9vzjzl3]
Clean cuts, what did you use?

A CNC punch press. Programing it is about half my job. Once the tools are in and the program is done, it punched in under a minute.

 

[Ansimp]

Nice work and great idea :good:

 

[Denver]

Very nice! :good:

 

[chuck c]

Good new / bad news.
The bad news:
I fit the parts according to my carefully done 3D CAD model and there is no way they will actually go together like that. Off by inches. :headscratch: WTF? Now, parts like this don't always match the dimensions given on the website, and with so many in this small space it wouldn't take much error to screw this up. But I measured them as best I could when I got them to confirm. I want to know why I'm so far off.

The good news:
There is a way they'll fit. See the pics. I'm short 2 45's to finish it but I can have them next week. It looks a little odd but I don't care. I salvaged the carb flange from my first experiment. Next week I'll do a bit of machining at work to make the carb adapter. This thing could be tested next weekend.

 

[joedrum]

wow chuck ...this is going to be deal to fit it all ...hang in there ...so much for the computer help...

 

[dan filipi]

This is getting interesting. Keep at it.

 

[slabghost]

The heads on these motor get a bit farther apart when the motor is warmed to operating temperature. You may want to connect the runners at least on one side of the center T with a hose to keep it from breaking.

 

[ekvh]

You can send a template to my house anytime.

 

[chuck c]

slabghost » Fri Mar 25, 2016 7:51 pm[/url]":1pd5c1iv]
The heads on these motor get a bit farther apart when the motor is warmed to operating temperature. You may want to connect the runners at least on one side of the center T with a hose to keep it from breaking.

They will be connected to the heads by rubber carb boots which should handle it, I hope.

 

[chuck c]

ekvh » Fri Mar 25, 2016 8:57 pm[/url]":10ka39a6]
You can send a template to my house anytime.

I wonder if there's enough interest to make a few for the gang here. The boss didn't mind me making one for myself but If I was to crank out more he might want some $. But as he is a Goldwing guy, he might not. It's a good cause. I'll play to that.

It's 20" x 10" and could ship between a couple sheets of cardboard. I could punch more holes to reduce the weight and lower the shipping price. Hmmmm. I might have to see what it would cost to ship. The bossman says it's cool to have personal stuff shipped to the work address because it's quite a bit cheaper. I have to assume going out is, too.

 

[slabghost]

Could it be done in a flexible plastic that could be rolled and shipped in a tube? Shipping would be a lot less. And I expect the material costs would also be lower.

 

[chuck c]

slabghost » Fri Mar 25, 2016 7:51 pm[/url]":28glrz6a]
The heads on these motor get a bit farther apart when the motor is warmed to operating temperature. You may want to connect the runners at least on one side of the center T with a hose to keep it from breaking.

After giving this a bit of thought, there are even more advantages to this. It makes assembly a bit easier since I can trombone- slide the right and left for a perfect fit, the tube length and assembly doesn't have to be so perfect. It will be easier to get on the bike in 3 parts than one. I figured on adding some support for the carb so all it's weight wouldn't be on the kind-of thin plastic tubing, altho it seems sturdy. I'm convinced. Rubber it gets.

 

[chuck c]

slabghost » Fri Mar 25, 2016 9:26 pm[/url]":xnsi7yv2]
Could it be done in a flexible plastic that could be rolled and shipped in a tube? Shipping would be a lot less. And I expect the material costs would also be lower.

Anything that flexible couldn't be made by the method I used. BUT.... I can print a 1:1 template with dimensions on 18 x 24 paper, fold it, and send it. You can transfer it to plywood on your end. Would that work? That would only cost a couple bucks each and could mail first class.

Also, mine is steel but though aluminum costs more it's a third the weight. I'd have to run the numbers to see which is cheaper- steel and heavy to ship or more expensive aluminum but less to ship.

 

[slabghost]

For myself personally I have a spare rack of carbs I can use to make a similar template. Trying to think how this can be more available. I wonder if a picture of your template could be made and then sized to properly print on say 4 sheets of paper? That would be a readily available download then.

 

[chuck c]

slabghost » Fri Mar 25, 2016 10:30 pm[/url]":2rnbj066]
For myself personally I have a spare rack of carbs I can use to make a similar template. Trying to think how this can be more available. I wonder if a picture of your template could be made and then sized to properly print on say 4 sheets of paper? That would be a readily available download then.

I think would be really hard to do because I'd have no control of printing. There's no guarantee it would print 1:1 when you print it out. I can make a dimensioned drawing to fit on letter size that could be followed by the user but it would not be 1:1 of course.

 

[ekvh]

The trombone idea would make it work for 1200's as well, but I guess laying a rack on a piece of plywood doesn't take that much.

 

[chuck c]

ekvh » Sat Mar 26, 2016 5:17 am[/url]":7gmdfqu7]
The trombone idea would make it work for 1200's as well, but I guess laying a rack on a piece of plywood doesn't take that much.

The only advantage of the paper template then is that you can work on your manifold before you remove the carbs from the bike. You can still ride it until you're ready to do the switch.

Is the only size difference between the 1100 and 1200 the side to side distance between the ports? Does anyone know that dimension?

 

[joedrum]

its the only difference ...but no i have never measured it