The fabrication thread.

[Jonnie Fraz]

It is a bit of a balancing act in that you want the bar to be strong enough to resist small impacts " rubbing", but in a bigger one you want it to give and absorb energy without destroying the chassis.

[dpritchard4]

so how do you guys make exhaust manifold flanges for your projects?? im wondering if there is a place where you get your dimms for your cnc program or if you take measurements yourself. im current a MET student who is in a class running FAE analysis on solidwork files. i would like to design a sr or kat manifold but cant find a place with dimmensions made for the flanges. any ideas?

[NismoPlsr]

Originally Posted by dpritchard4

so how do you guys make exhaust manifold flanges for your projects?? im wondering if there is a place where you get your dimms for your cnc program or if you take measurements yourself. im current a MET student who is in a class running FAE analysis on solidwork files. i would like to design a sr or kat manifold but cant find a place with dimmensions made for the flanges. any ideas?

Scan a gasket then trace it in Adobe Illustrator then import the AI file, or something along those lines.

[duffman1278]

Originally Posted by NismoPlsr

Scan a gasket then trace it in Adobe Illustrator then import the AI file, or something along those lines.

Better yet, just take the scanned file of the gasket and drop it into Solidworks and trace it on there.

[atutt]

.....Better yet, buy one already made?

[godrifttoday]

Sometimes u just can't re-invent the wheel

[NismoPlsr]

It sounded like his point was to get a model in CAD so he could to some FEA on it.

[dpritchard4]

Originally Posted by NismoPlsr

It sounded like his point was to get a model in CAD so he could to some FEA on it.

exactly what i wanted

i never thought about scanning the gasket, also didnt know you could trace in solidworks (been an autocad user for 8 yrs, finally switching over)


and if i ever build one i will deff buy a pre-built flange

[trickey1991]

bottom of my new intake manifold before final weld.

[wisDOMination]

Hey guys,
In the market for a welder right now. Stuck between a Miller DVI2 and the newer 211. I plan on using it for custom car fab shit (tubs, bash bars, exhaust/intercooler piping, etc)
Don't plan to do production type stuff or anything, nor does it have to be portable. I'll be using it both at home and at a shop.
Now here's the deal. If I go with the DVI2, it would be a used one that my landlord is tryna sell. Don't know much about it, but he said it wasnt used a lot, and is thinking of selling it for $1000. As for the 211, I'd have to head down to Air Gas and buy a brand new one, which should be a little more than $1000.
Regardless of price, which one would be a better buy?
Much thanks in advance

[Karlitos]

Originally Posted by dpritchard4

exactly what i wanted

i never thought about scanning the gasket, also didnt know you could trace in solidworks (been an autocad user for 8 yrs, finally switching over)


and if i ever build one i will deff buy a pre-built flange

Yeah you can import a picture and post it on a plane in SW. Then trace or maybe sketch identities.

why use cosmosxpress on SW? Its just a testing thing, no where near as good as using Abaqus/Catia or some other real FEA. We used SW just for some quick things in SAE. Our FEA class and major parts went onto abaqus.

[duffman1278]

Originally Posted by dpritchard4

exactly what i wanted

i never thought about scanning the gasket, also didnt know you could trace in solidworks (been an autocad user for 8 yrs, finally switching over)


and if i ever build one i will deff buy a pre-built flange

Why FEA it? You don't know any of the loads unless you get a DAQ. And I really doubt you'll be looking into modal analysis or stresses due to thermal loading and or impulse reactions. Karlitos is right also, SW cosmos is not that great. It doesn't even let you define your own mesh and tetrahedral is the least accurate element.

[az_240]

First time welding suspension arms.... harder than expected.

Wanting to toss these turds in the trash

[bb4_96]

cosmos is weak.. get ansys

[ManoNegra]

Originally Posted by dpritchard4

so how do you guys make exhaust manifold flanges for your projects?? im wondering if there is a place where you get your dimms for your cnc program or if you take measurements yourself. im current a MET student who is in a class running FAE analysis on solidwork files. i would like to design a sr or kat manifold but cant find a place with dimmensions made for the flanges. any ideas?

late I know.

we use the CMM at work to gather as many data points as needed.
Then plot them in Gibbs, build the parts and transfer the G Code to a CNC machine.

[Motary]

Originally Posted by az_240

First time welding suspension arms.... harder than expected.
PEEEKTURE
Wanting to toss these turds in the trash

Try welding like this, in a row of coins:

Random google image:



Also set your amps and wire feed so the weld would penetrate and would sink a tiny bit inwards or be level, but never make mountains

[Chamb-O]

here is a charge pipe I did for an e36 m3 the other day



and all painted up


small complex pipes kick my ass haha

[atutt]

I find IC tubing to be the biggest pain in the ass...

Something about it that I can never get perfect.

[Chamb-O]

I usually find it really easy- 2 points that have a little bit of wiggle room with couplers
small complex pipes like these always kick my ass

not so much the fitment and welding
it is just really hard to tell a customer that I spent 3 hrs on less than a foot of piping

[shiftdrift]

Wishbone mounts fabbed from scratch

[s14unimog]

Originally Posted by az_240

First time welding suspension arms.... harder than expected. Wanting to toss these turds in the trash

More prep. I bet you were fighting contamination issues from the e-coat & paint.

I'm going to switch it up a bit from all the welding pics. Here is a plastic electrical control panel I made for my s14.

[az_240]

Originally Posted by s14unimog

More prep. I bet you were fighting contamination issues from the e-coat & paint.

A friend welded those... We're both n00bs at fabrication and were practicing welding the cutout material together before going onto the arms... Everything welded fine and we didn't remove the coating.... just wiped down with isopropyl alcohol.

Removed the paint on the arms with 60 grit sandpaper (didn't have a grinder on hand) and prepped with alcohol... Still had popping. Guess I need to use a grinder and remove the coating on the cutouts next time.

What they look like now... got another pair on the way to try again.

[MikeySand]

wire brush to bare metal then wipe down with non-chlorinated brake cleaner or acetone. works well for me.


edit:

forgot i was logged in on my buddies account


ka-titties

[D.Adams]

Originally Posted by az_240

A friend welded those... We're both n00bs at fabrication and were practicing welding the cutout material together before going onto the arms... Everything welded fine and we didn't remove the coating.... just wiped down with isopropyl alcohol.

Removed the paint on the arms with 60 grit sandpaper (didn't have a grinder on hand) and prepped with alcohol... Still had popping. Guess I need to use a grinder and remove the coating on the cutouts next time.

What they look like now... got another pair on the way to try again.

Make sure your wire speed and temp range is set rite. Looks like you arent running hot enough and your wire speed is set to fast. I use mostly the what some call stack of dimes method on welding arms and cage work. I start then stop then start again about 1/2 way into the first bead and just do that till im finished.

this might help MIG WELDING - Mig welding techniques for high end metal fabrication. MIG Welding TIG Welding Tube Work Plate Work


Some of my recent work on a friends car.

The rear sub fram bracing



Boxed in RUCA mount


Rear trunk floor pan. What we put in plave of the spare tire shit pan


stitch weld


Rear cage mount boxes





The cage













I have done alot more just dont have time to post 8 pages worth of pictures lol .. Or for you premium members we have a built thread there
http://zilvia.net/f/premium-member-b...u-city-az.html

[josh_schul]

D.Adams ...Thanks for the link on the mig welding! Very helpful! Been lurking here and it has helped me out big time!

[D.Adams]

Originally Posted by josh_schul

D.Adams ...Thanks for the link on the mig welding! Very helpful! Been lurking here and it has helped me out big time!

yeah man anytime.

If you have any questions shoot me a pm. Im no crazy godly welder but i did go to school for welding.

That website i linked you to has alot of good info on it for people just starting off.

http://www.profabricationtechniques.com/

[PoorMans180SX]

Designed by me, welded by my boss.

[atutt]

Originally Posted by D.Adams

Make sure your wire speed and temp range is set rite. Looks like you arent running hot enough and your wire speed is set to fast. I use mostly the what some call stack of dimes method on welding arms and cage work. I start then stop then start again about 1/2 way into the first bead and just do that till im finished.

Dear God I hope I'm misunderstanding that.

You're not letting off the trigger by "stopping" are you?

I'm guessing you mean you're pausing?

[Chamb-O]

Originally Posted by PoorMans180SX

Designed by me, welded by my boss.

Is that a treadstone cast collector?
if so, how was the quality on the casting?

[PoorMans180SX]

It is indeed. It was quite nice, I cleaned it up a little on the inside, and ground one of the runners just a bit to get it perfectly flat. This is the prototype though, so I can't speak for the actual production units.