|
D2 - Fuel and Exhausts Everything to do with getting fuel into the engine, and fumes back out again |
|
Thread Tools | Display Modes |
#1
|
|||
|
|||
Exhaust tinkering
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!
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 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) Drill mounting holes Then stick it in the lathe and turn a chamfer in to one face to match the pipe and then cut the lovely thing in half 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. Then attacked it with the mig, and we have this 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 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 |
#2
|
|||
|
|||
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
__________________
2002 D2 S8 - Avus Silver, Valcona red leather, Dark Myrtle wood inserts, Heated rear seats, Heated windscreen, Auto dim rear view mirror, Bose, Xenon Plus, Servotronic, Extended leather, Heat & UV Reflective glass & Ski hatch. Gearbox went bang but she's sleeping safely away. |
#3
|
|||
|
|||
There are so many threads on here that make me think 'What have I done?'
Are you really attached to your day job MJ? |
#4
|
|||
|
|||
Quote:
Quote:
Finished this off just now. The second piece was much easier having learned a few things on the first. We end up with this: Pretty happy with that, although yes, 10mm plate was slightly overkill 8mm next time, and make the centre hole a bit larger too. |
#5
|
|||
|
|||
Very cool
__________________
Andy. Current cars: BMW i4 M-Sport Peugeot 207 (the sons) Triumph Daytona 675 (2017 reg) =========================== Gone but not forgotten Ford Focus ST-2 Mk3 (the wifes) (stolen Oct 2023) 1972 T2 Bay Window Camper (Slow) Audi TT Mk1 225 - now with coil-overs and a 7inch touchscreen infotainment centre 2003 A8 Sport 4.2 (with ACC & LPG) (Feed up with all the issues so passed it on to a forum member) 2000 A8 FL QS 4.2 (with RNS-E - Nice) (Engine poorly so sold on to be brought back by someone who has the time) |
#6
|
|||
|
|||
I plan to drive mine eventually
|
#7
|
||||
|
||||
Hey you.
You should have said, think I have some more somewhere, I had them lasered, with the small holes
__________________
1996 A8 4.2 QS. Bose, Solar roof, um...um... rally sport towbar. Now gone to a new home as the Traders 8. Bright yellow bus o love. |
#8
|
|||
|
|||
I didn't want to draw your attention to the quality of my welding
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 |
#9
|
||||
|
||||
Quote:
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
__________________
1996 A8 4.2 QS. Bose, Solar roof, um...um... rally sport towbar. Now gone to a new home as the Traders 8. Bright yellow bus o love. |
#10
|
|||
|
|||
I was putting my 3D brain into action and trying to think of another way of solving that without welding.....
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.
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.). 2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one! Finally: gone, but not forgotten..... 1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors. e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later) 1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer. And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850! Last edited by HPsauce; 19th February 2020 at 03:07 PM. |
|
|