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-   -   Exhaust tinkering (https://forum.a8parts.co.uk/showthread.php?t=15524)

MikkiJayne 17th February 2020 08:40 PM

Exhaust tinkering
 
9 Attachment(s)
The D2 S8 has a donut-joint between the passenger side downpipe and cat, to allow the cat to be removed for access to the gearbox. Unfortunately most of them are looking pretty crusty by now, this one particularly so!

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

This is beyond salvation, and obviously unobtanium now - Prestige don't have any, and I don't have any good ones so time for a new solution.

Start with a 3D printed prototype to test fitment

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

That fitted the pipe quite well, so I sent the file to the local steel stockholder who CNC plasma cut me some flanges (minus small holes as the plasma won't cut them)

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

Drill mounting holes

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

Then stick it in the lathe and turn a chamfer in to one face to match the pipe

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

and then cut the lovely thing in half :(

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

Alas, this is the only way to get it on to the pipe.

Using the other flange, I bolted it all together to get it straight while back on the pipe. The pipe is covered in anti-spatter spray and I also used some aluminium foil between the new flange and the pipe so I didn't weld them both together.

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

Then attacked it with the mig, and we have this

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

http://forum.a8parts.co.uk/attachmen...1&d=1581970988

I think this should work just fine, and I went slightly overkill and made it from 10mm plate, so it should last a few more years :D I need to do the same again to the cat which has the other side of this tomorrow, and then hopefully it will all bolt back together nicely +++

Davey Blueeyes 17th February 2020 09:55 PM

Flipping Nora. Wouldn't the world be a better place if MJ was in charge of it?!

Honestly, I think you are about five years away from restarting complete D2 production from Devon.

If you do I'll have one +++

Sit down, Waldo 18th February 2020 07:47 AM

There are so many threads on here that make me think 'What have I done?' :eek2:

Are you really attached to your day job MJ? :D

MikkiJayne 18th February 2020 05:26 PM

3 Attachment(s)
Quote:

Originally Posted by Sit down, Waldo (Post 155767)
There are so many threads on here that make me think 'What have I done?' :eek2:

#D2Life :ROFL: I plan to drive my D2 until the dinosaur squeezings run out, and I'll take as many others along for the ride as possible +++

Quote:

Originally Posted by Sit down, Waldo
Are you really attached to your day job MJ? :D

I hate it, but it pays the bills and means that D2s can still be fun. If I did them full time, it would stop being fun ;)

Finished this off just now. The second piece was much easier having learned a few things on the first. We end up with this:

http://forum.a8parts.co.uk/attachmen...1&d=1582046540

http://forum.a8parts.co.uk/attachmen...1&d=1582046540

http://forum.a8parts.co.uk/attachmen...1&d=1582046540

Pretty happy with that, although yes, 10mm plate was slightly overkill :D 8mm next time, and make the centre hole a bit larger too.

gninnam 18th February 2020 06:32 PM

Very cool :D+++

Sit down, Waldo 18th February 2020 08:53 PM

Quote:

Originally Posted by MikkiJayne (Post 155784)
#D2Life :ROFL: I plan to drive my D2 until the dinosaur squeezings run out, and I'll take as many others along for the ride as possible +++

I plan to drive mine eventually :D

Dezzy 19th February 2020 11:17 AM

Hey you.


You should have said, think I have some more somewhere, I had them lasered, with the small holes :p

MikkiJayne 19th February 2020 11:30 AM

I didn't want to draw your attention to the quality of my welding :D

The next batch I will get done with either a better plasma or a laser, but that has to go up to Tivvy and takes a few days. These were done by Conibeare's same-day so I couldn't be picky ;)

Dezzy 19th February 2020 03:16 PM

Quote:

Originally Posted by MikkiJayne (Post 155800)
I didn't want to draw your attention to the quality of my welding :D

The next batch I will get done with either a better plasma or a laser, but that has to go up to Tivvy and takes a few days. These were done by Conibeare's same-day so I couldn't be picky ;)

They're tough to weld and make it look pretty. Think the ones I had cut were 6 or 8 thk so didn't need the edge prep.

I've not had much luck with laser people, getting back is too much trouble, getting it done in the next week is to much trouble, unfortunately cant go stand next to the operator and give him sweets till it's done anymore.

Mirror polished Stainless next time :D

HPsauce 19th February 2020 03:50 PM

1 Attachment(s)
I was putting my 3D brain into action and trying to think of another way of solving that without welding..... :Confused:

Could you make each flange out of a pair of interlocking U-shaped pieces that slot onto the pipe, one from each side, maybe about 4mm thick? It should all pull together nicely once the bolts are fitted, though may need some clips (or just adhesive) to hold together while fixing?

I know a simple version as in my sketch won't apply pressure all round, that would need a protrusion on the second plate which might be tricky to make.


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