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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 15750
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Sat Mar 30, 2019 7:00 pm    Post subject: 3.6 Cam Locking Tool Reply with quote

I've been asked a couple of times recently if I have any of the 3.6 cam locking tools I used to make, so the other week I did a run of them at work. If anyone's interested in getting one then ping me a message for details.

As I know some of you like seeing the Engineering processes I thought I'd do a bit of a write-up on the manufacturing process:

I make the tools from Gauge Plate. It's a Tool Steel in it's annealed state so can be machined. It can be hardened if required but for this job it's tough enough in its annealed state. More here:
https://www.westyorkssteel.com/tool-steel/gauge-plate-ground-flat-stock/


First job is to chop the plate up into smaller pieces and drill a couple of holes in them so they can be mounted on a jig ready for maching the profile on my CNC Miller..




The jig is pretty simple. Just a block of Aluminium with a couple of M6 tapped holes in (same position and orientation as the drilled holes in the plate.




Each piece then bolts directly on the jig ready for machining.




Once all the tooling is set up for each process: roughing out profile, finishing profile, machining 8mm slot, machining step, then the action can begin.

First job is to rough out the profile using a 'ripper' End Mill.


Open Youtube Page



Here it is roughed out ready with 0.1mm left on for finishing.




Then a finish cut is done with a standard End Mill to take the profile to size and leave a smoother finish on.




Next process is to machine a stepp across the central part that bolts to the engine block.


Open Youtube Page



Like so:




.....and the last process on the Miller is to machine the 8mm slot in the central part (for the bolt to go through when locking the cams.


Open Youtube Page





There's all the milling done.




The material is ground to 6mm + a few hundredths so to ensure it goes into the slots on the cams and to make it look a bit nicer I give it a quick lick on the top & bottom on the Surface Grinder.




Open Youtube Page



Shazaam - the finished article.




A quick deburr with an oil stone and demagnetise it to remove any magnetism from the magnetic chuck on the Surface Grinder and they're good to go:








Hope you enjoyed "A day in the life of Alex" Smile
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2000 Manual 996 C4 Arctic Silver Convertible


 
  
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MisterCorn
Long Beach


Joined: 08 Jan 2011
Posts: 6847
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Sat Mar 30, 2019 7:05 pm    Post subject: Reply with quote

Certainly did Thumb
MC
 
  
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 15750
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Sat Mar 30, 2019 10:26 pm    Post subject: Reply with quote

For those with a sharp eye, I missed documenting the last process of squaring the corners out on the lugs that lock in the cams. I did this with all the tools stacked together on my Surface Grinder.
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Kingb4
Spa-Francorchamps


Joined: 20 Jan 2018
Posts: 342
Location: Beds/Bucks


PostPosted: Sat Mar 30, 2019 10:36 pm    Post subject: Reply with quote

Great write up.....

Thanks for sending mine so quickly.....much appreciated!
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2002 996.2 C2 Cabriolet
 
  
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JTT
Trainee


Joined: 11 Nov 2015
Posts: 76
Location: Halifax, NS Canada


PostPosted: Sat Mar 30, 2019 10:40 pm    Post subject: Reply with quote

Nice work Alex! Thanks
 
  
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 15750
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Sat Mar 30, 2019 10:41 pm    Post subject: Reply with quote

No problem my friend. We're all in it together and I always like to bring something to the party. Smile
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JTT
Trainee


Joined: 11 Nov 2015
Posts: 76
Location: Halifax, NS Canada


PostPosted: Sat Apr 20, 2019 10:33 am    Post subject: Reply with quote

Hey Alex, my tool arrived today! Beautiful work! Hard to put it away in tool box as it's so pretty....might have to mount on the wall thumbsup Thanks!
 
  
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Alex
Le Mans
Le Mans


Joined: 06 Mar 2014
Posts: 15750
Location: The Ribble Valley, Lancashire

2000 Porsche 996 Carrera 4

PostPosted: Sat Apr 20, 2019 11:26 am    Post subject: Reply with quote

worship
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