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Jamesx19
Monza


Joined: 10 Jul 2015
Posts: 166
Location: Brighton


PostPosted: Sat Jun 24, 2017 11:44 pm    Post subject: Reply with quote

Cheers Jimk04. Interesting. Wonder if anyone has tried making a mass damper for the front pulley?
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1998 C2 Manual
 
  
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jimk04
Newbie


Joined: 10 Dec 2013
Posts: 33



PostPosted: Sat Jun 24, 2017 11:47 pm    Post subject: Reply with quote

The dfi engines 2009 on have a harmonic damper front pulley.
Some guys in the US made some for the Mezger engine.
I don't really see how such a small diameter...light weight item can have much of an influence on the rest of the rotating mass.
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MisterCorn
Zolder


Joined: 08 Jan 2011
Posts: 5145
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Sat Jun 24, 2017 11:52 pm    Post subject: Reply with quote

The only time I have seen coolant issues on my C2 has been at high ambient/ low vehicle speed conditions. I don't have the data to say if this is a lack of flow or a lack of airflow though. I haven't seen it on other cars I own. I have spent a week driving my 560 SEC in 30+ degree ambient conditions with the tempersture rarely going over 80. My C2 would be up close to 100 at the first sniff of traffic. If non of the other learned menbers have an answer I will hit mine with a bunch of thermocouples and see what is going on.

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jimk04
Newbie


Joined: 10 Dec 2013
Posts: 33



PostPosted: Sat Jun 24, 2017 11:55 pm    Post subject: Reply with quote

All I can say is I have sat in traffic in 30 degree heat for an hour on way to le mans and mine never got about 85 on the factory clocks....with my 4" udp
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1012



PostPosted: Thu Jul 06, 2017 1:49 pm    Post subject: Reply with quote

The plenum is here to allow fitment of the 82mm gt3 throttle body.

Quite strange to draw something on CAD and it arrives in the flesh via Pat the postman Thumb

This will require some hand finishing, jig drilling and fitting of inserts to allow bolting on of the TB and a small amount of plastic clean up. The min wall thickness at any point is 3mm so it's strong and surprisingly light.

Based on this version I will tweak the design but this unit will run on the engine.



 
  
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poppopbangbang
Nürburgring


Joined: 25 May 2015
Posts: 450



PostPosted: Fri Jul 07, 2017 12:31 pm    Post subject: Reply with quote

Is that printed in ABS Harv?
 
  
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1012



PostPosted: Fri Jul 07, 2017 1:39 pm    Post subject: Reply with quote

Yes it is printed abs Matt, the finish is a little grainy but that's one of the limitations and the part doesn't need to look really pretty (function over form....)

It could probably be metal printed too (though not looked into this and I expect would be much more expensive).

Congrats on your engine's re-birth, been following your thread.

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poppopbangbang
Nürburgring


Joined: 25 May 2015
Posts: 450



PostPosted: Fri Jul 07, 2017 11:18 pm    Post subject: Reply with quote

I think you might struggle with ABS, I did. The problem is two fold, with the GT3 throttle body you can't effectively support the body off the top of the PAS pump like it is as standard so the entire weight of the body, intake hose etc. is hanging off it which then causes the plenum to fail around the throttle body flange. Secondly ABS isn't that stable so with the ambient temp in the bay at around 60 degrees I found the clamping load of the bolts pulled the flange over time which then caused and air leak.

This was the final version I arrived at:



You can see I essentially deleted the flange and extended the bolt "holes" back along the piece to add strength and remove the step of the flange. I also added additional webbing and chamfers to reduce the stress risers at the transitions and increase overall strength.

We printed this in carbon reinforced nylon with stainless thread-serts printed in. It pretty much worked but again the stresses on it from it supporting everything from the plenums up were a bit too much for me to be comfortable with - plus printing carbon reinforced nylon is a bastard and the nozzles on our kit are REALLY expensive Hand so as it was taking one nozzle to print one plenum I didn't really want to do it again if it did fail. In the end I just ordered an IPD one as it was cheaper than machining one from solid.

It might be worth speak to 3D Systems advance prototype division as they offer epoxy resin printing which would be strong enough. Failing that maybe some way of additionally bracing it externally off the bottom two throttle body mounting bolts?

If you want a copy of my CAD let me know and I will send it over. All the best with it - it would be great to see someone succeed when I gave up and took the easy option Thumb
 
  
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Harv
Suzuka


Joined: 18 Sep 2014
Posts: 1012



PostPosted: Sat Jul 08, 2017 8:43 am    Post subject: Reply with quote

Matt

Thanks for your feedback and findings, very useful Thumb

My route has been to stick very close to the oem one with subtle changes. My plan is to support this off the pas housing bolts, that will require fashioning of a bracket, two places would be better than one.

There are some nice barbed brass inserts that I've seen which I will trial (probably inserted with an expoxy resin) to hold The TB to the plenum. And nothing more than a nip up of the bolts should be required, this uses a rubber o ring for sealing.

Did you consider having it 3D printed but in metal?

I'll drop you a PM.

Cheers
Harv


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Dammit
Spa-Francorchamps


Joined: 23 Sep 2016
Posts: 366



PostPosted: Sat Jul 15, 2017 10:28 pm    Post subject: Reply with quote

Hi Harv, very interested in how you get on with this and also wondering if you knew of a larger throttle body option for those of us with a cable actuated throttle?
 
  
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