Exhaust tinkering
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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 +++ |
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 +++ |
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 |
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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. |
Very cool :D+++
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Hey you.
You should have said, think I have some more somewhere, I had them lasered, with the small holes :p |
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 ;) |
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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 |
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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. |
I can 3D print such a thing very easily, but without access to a CNC mill its practically impossible to produce it in steel given the cost and time constraints of fixing an exhaust system ;)
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Another excellent engineering piece from MJ!
Keep going!! +++ |
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Though I've had another idea that would be much easier...… :cool:
Make your piece as originally designed, 8mm maybe, but drill 6 holes - 3 each on opposite sides. 2 identical pieces for 1 joint. Then make 2 cuts to create the piece shaped like mine and retain the cutout segments which will have one hole in each. Fit the main pieces over the pipes from opposite sides, insert the 4 corner bolts and tighten enough to hold in place. Then slide in the two sections previously cut out and fit 2 further bolts to make a complete fitment. Tighten. The repair pieces might need to be slightly larger or a subtly different shape to accommodate the extra bolts. More Hexagonal maybe, like the attached sketch? |
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Spot on Sean. +++
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