InsaneSwede's Astra MKI - Page 9

InsaneSwede · 14-09-2007, 16:53

Thank you guys for all the good response.
Keep viewing, there are more updates to come.

here´s a project for a friend.
He wanted a inletmanifold for his calibra and asked me to build one, ofcourse i can.
some pics of todays work:

Collected parts:

beginned with drilling a plate for the runners:

Then i pressed the runners oval as the porst on flange: (they need more shaping,but i´ll do that as i weld them into flange)

then i cut open the plenum for the plate: (to the left in picture)

Started to line up the runners for tackwelding:

Almost done: (but theres a lot of work left)

Then i recevied the coils today and started to look at that a little.
They will fit with a little mods to them and valve cover.
Piccies:

Tight fit, but there will be small mods to valvecover to get the coils lower(to reach the plug)

That´s all for today folks..
more tomorrow.(or sunday)

Cheers

Drizz · 14-09-2007, 16:57

nice

InsaneSwede · 14-09-2007, 17:04

My ideas of this model of coils is to 'glue' them into aluminiumcover to get some cooling on them and to get them ridgid.

Somebody knows of some heatransfering glue? (epoxi)

Rgds
Patrick

Kev 180iE · 14-09-2007, 18:26

what about the adhesive used to glue computer processors to heatsinks?

donvaux · 14-09-2007, 18:40

artic silver i think it's called but i don't think it's an adhesive not 100% sure though

Kev 180iE · 14-09-2007, 18:41

yeah something like that - silver compound of some description - it is adhesive, but possibly not enough - it's not as if it has to withstand any stress once everything is installed in a PC case.

donvaux · 14-09-2007, 18:44

maybe you could use artic silver on top and glue the sides to the plug cover if they will fit up in

InsaneSwede · 14-09-2007, 20:22

Quote:

Originally Posted by donvaux

maybe you could use artic silver on top and glue the sides to the plug cover if they will fit up in

Thats one of my ideas.

When it´s done it will be almost like saab´s coilcasette and with a nice connectionplug at the end where the originally leads are going from distributor.

donvaux · 14-09-2007, 20:28

sounds good less clutter more space for bhp lol

Rs1 · 14-09-2007, 20:50

Patrick did you make the inlet that is on your engine aswell?
What do you base your decissions on for runner length and plenum volume?
What solution do you have for the water piping that is incorporated in the inlet flange?

InsaneSwede · 15-09-2007, 07:45

Rs1:
Yes i did that one too.
Runner length is based on 'pulsation' and is 31cm long (to get the strongest pulse i should have double the length,but theres no room)
For plenum volume i just base it on 1.5 times the enginevolume to the least.
Mine should have 3.45litre inside but i´ve got almost 4 litre(a shot beside the target, but it doesn´t really matter that much,more important to get even flow over runners)

Waterpipe solution,, well,, small alupipes and a lot of work

Rgds

leesturbo · 15-09-2007, 19:58

rob for the water i'd just use a blanking plate
then tap threads in for either dash jic fittings
for braided hoses or just screw hose tails in?
is there 2 threaded holes free to clamp a blank
plate down? i can't remember?

InsaneSwede · 16-09-2007, 13:18

A little update from yesterday and todays work, maybe one update later tonight when i´m welding on inlet.

here´s my complete 3,5" exhaustsystem:
as car is under weightloss program and no room for a big exhaust enderneeth the car my solution is as on Norrisdesigns evo

Nice welds:

Tight fit:

Exhausttip not done yet:

Drizz · 16-09-2007, 13:23

Noise!

vauxhallparts · 16-09-2007, 13:23

how much would you charge to build another inlet like yours and ready to fit inc fuel rail

16vastraturbo · 16-09-2007, 13:30

Quote:

Originally Posted by vauxhallparts

how much would you charge to build another inlet like yours and ready to fit inc fuel rail

same here how much?

vauxhallparts · 16-09-2007, 13:32

group buy lol

InsaneSwede · 16-09-2007, 15:50

Quote:

Originally Posted by Drizz

Noise!

Race car... who care?

honestly,, there will be an insert to lower noice at cruising.

here´s also an small update on inlet,

made the 'cone' underneeth to even the flow over runners, as you can see the 90 degree bend will connect to that cone.

Between the cone and 'main plenum' there are a 'slit' (word?) that is 350mm long and 25mm wide.
Can take a picture on that later.

pic:

Cheers..

InsaneSwede · 16-09-2007, 15:53

Quote:

Originally Posted by vauxhallparts

group buy lol

If you all aint in to much of a hurry i´ll calculate the costs at time spent on this.
then i can give you some price.

This is pure handwork with out the flanges.
it takes some time.

And i need to know what cars to fit them into.

Rgds

vauxhallparts · 16-09-2007, 19:23

in the back of a nissan sunny. room is not a probem and the intake can be either side,also can use standard fuel rail if thats easier

16vastraturbo · 16-09-2007, 23:11

astra mk3 c20let

InsaneSwede · 18-09-2007, 08:23

Hey you Frenchmen´s that reads this thread.
Don´t be afraid to ask questions.

I won´t bite...(only if you ask in french)

CraigGreen · 18-09-2007, 09:12

Wow. Inlet is beautiful, exhaust is crazy!

**Nobbie** · 18-09-2007, 09:50

THats what i want to do with my exhaust, and apparently its legal of it exits on the off side.

Like the inlet but would like to see it build, as beardy's one was looking good too with the vr 2. The main problem is making sure the even distributio of volume, and flow. If there is a sharpish bend on the inlet cylinder no 1, or 4 will not have the same as 2 or 3, even on forced induction.

InsaneSwede · 18-09-2007, 14:42

The air comes into the plenum 'underneeth' the velocitytrumpets(stacks) and have no cylinder to 'favorize'
it´s the same 'resistance' to all 4 runners.
Almost like this:

very much like cossie std plenum but more efficiant distributing of air into plenum.
And then far better plenum as there are no 'flat walls' behind the trumpets, (can produce unwanted rameffect)

14-09-2007, 16:53	#201
InsaneSwede MIGWeb User Join Date: Oct 2002 Location: Sweden Drives: Astra MkI iTrader: (0) Posts: 666	Thank you guys for all the good response. Keep viewing, there are more updates to come. here´s a project for a friend. He wanted a inletmanifold for his calibra and asked me to build one, ofcourse i can. some pics of todays work: Collected parts: beginned with drilling a plate for the runners: Then i pressed the runners oval as the porst on flange: (they need more shaping,but i´ll do that as i weld them into flange) then i cut open the plenum for the plate: (to the left in picture) Started to line up the runners for tackwelding: Almost done: (but theres a lot of work left) Then i recevied the coils today and started to look at that a little. They will fit with a little mods to them and valve cover. Piccies: Tight fit, but there will be small mods to valvecover to get the coils lower(to reach the plug) That´s all for today folks.. more tomorrow.(or sunday) Cheers __________________ Kadett GT/E Sometimes you are the bug sometimes you are the windsheild

14-09-2007, 20:50	#210
Rs1 MIGWeb User Join Date: Dec 2004 Location: Newcastle Drives: LET...coming soon iTrader: (10) Posts: 7,806	Patrick did you make the inlet that is on your engine aswell? What do you base your decissions on for runner length and plenum volume? What solution do you have for the water piping that is incorporated in the inlet flange? __________________ "THE ROB"

16-09-2007, 13:23	#215
vauxhallparts MIGWeb User Join Date: Feb 2005 Location: harlow essex Drives: into lamp posts iTrader: (3) Posts: 1,864	how much would you charge to build another inlet like yours and ready to fit inc fuel rail __________________ vauxhallparts http://i57.photobucket.com/albums/g2...h/DSC00495.jpg

18-09-2007, 09:12	#223
CraigGreen MIGClub Member Join Date: Jun 2003 Location: way-out-west Drives: tempermental VW iTrader: (9) Posts: 15,120	Wow. Inlet is beautiful, exhaust is crazy! __________________ it's a C20XE not a fookin Redtop FFS

18-09-2007, 09:50	#224
Nobbie Central Regional Coordinator / Moderator Join Date: Nov 2001 Location: Hemel Hempstead Drives: Mk3 Astra GSi XE iTrader: (3) Posts: 10,560	THats what i want to do with my exhaust, and apparently its legal of it exits on the off side. Like the inlet but would like to see it build, as beardy's one was looking good too with the vr 2. The main problem is making sure the even distributio of volume, and flow. If there is a sharpish bend on the inlet cylinder no 1, or 4 will not have the same as 2 or 3, even on forced induction. __________________ Central Region Co-ordinator Central Region Forums/Events

14-09-2007, 16:57	#202
Drizz MIGWeb User Join Date: Jul 2001 Location: Suffolk Drives: Audi QTS, Defender iTrader: (27) Posts: 14,010	nice

14-09-2007, 17:04	#203
InsaneSwede MIGWeb User Join Date: Oct 2002 Location: Sweden Drives: Astra MkI iTrader: (0) Posts: 666	My ideas of this model of coils is to 'glue' them into aluminiumcover to get some cooling on them and to get them ridgid. Somebody knows of some heatransfering glue? (epoxi) Rgds Patrick

14-09-2007, 18:26	#204
Kev 180iE MIGWeb User Join Date: Nov 2004 Location: Huntingdon Drives: Opel Astra 180iE iTrader: (10) Posts: 1,812	what about the adhesive used to glue computer processors to heatsinks?

14-09-2007, 18:40	#205
donvaux MIGClub Member Join Date: Jul 2005 Location: pontypool, s.wales Drives: Astra GSI iTrader: (14) Posts: 2,782	artic silver i think it's called but i don't think it's an adhesive not 100% sure though

14-09-2007, 18:41	#206
Kev 180iE MIGWeb User Join Date: Nov 2004 Location: Huntingdon Drives: Opel Astra 180iE iTrader: (10) Posts: 1,812	yeah something like that - silver compound of some description - it is adhesive, but possibly not enough - it's not as if it has to withstand any stress once everything is installed in a PC case.

14-09-2007, 18:44	#207
donvaux MIGClub Member Join Date: Jul 2005 Location: pontypool, s.wales Drives: Astra GSI iTrader: (14) Posts: 2,782	maybe you could use artic silver on top and glue the sides to the plug cover if they will fit up in

14-09-2007, 20:28	#209
donvaux MIGClub Member Join Date: Jul 2005 Location: pontypool, s.wales Drives: Astra GSI iTrader: (14) Posts: 2,782	sounds good less clutter more space for bhp lol

15-09-2007, 07:45	#211
InsaneSwede MIGWeb User Join Date: Oct 2002 Location: Sweden Drives: Astra MkI iTrader: (0) Posts: 666	Rs1: Yes i did that one too. Runner length is based on 'pulsation' and is 31cm long (to get the strongest pulse i should have double the length,but theres no room) For plenum volume i just base it on 1.5 times the enginevolume to the least. Mine should have 3.45litre inside but i´ve got almost 4 litre(a shot beside the target, but it doesn´t really matter that much,more important to get even flow over runners) Waterpipe solution,, well,, small alupipes and a lot of work Rgds

15-09-2007, 19:58	#212
leesturbo MIGWeb User Join Date: Jun 2003 Location: now in a evo Drives: 1.4bar = 356bhp :-) iTrader: (7) Posts: 6,697	rob for the water i'd just use a blanking plate then tap threads in for either dash jic fittings for braided hoses or just screw hose tails in? is there 2 threaded holes free to clamp a blank plate down? i can't remember?

16-09-2007, 13:18	#213
InsaneSwede MIGWeb User Join Date: Oct 2002 Location: Sweden Drives: Astra MkI iTrader: (0) Posts: 666	A little update from yesterday and todays work, maybe one update later tonight when i´m welding on inlet. here´s my complete 3,5" exhaustsystem: as car is under weightloss program and no room for a big exhaust enderneeth the car my solution is as on Norrisdesigns evo Nice welds: Tight fit: Exhausttip not done yet:

16-09-2007, 13:23	#214
Drizz MIGWeb User Join Date: Jul 2001 Location: Suffolk Drives: Audi QTS, Defender iTrader: (27) Posts: 14,010	Noise!

16-09-2007, 13:32	#217
vauxhallparts MIGWeb User Join Date: Feb 2005 Location: harlow essex Drives: into lamp posts iTrader: (3) Posts: 1,864	group buy lol

16-09-2007, 19:23	#220
vauxhallparts MIGWeb User Join Date: Feb 2005 Location: harlow essex Drives: into lamp posts iTrader: (3) Posts: 1,864	in the back of a nissan sunny. room is not a probem and the intake can be either side,also can use standard fuel rail if thats easier

16-09-2007, 23:11	#221
16vastraturbo MIGWeb User Join Date: Aug 2006 Location: sunny swad, derby Drives: mk3 astra turbo iTrader: (0) Posts: 597	astra mk3 c20let

18-09-2007, 08:23	#222
InsaneSwede MIGWeb User Join Date: Oct 2002 Location: Sweden Drives: Astra MkI iTrader: (0) Posts: 666	Hey you Frenchmen´s that reads this thread. Don´t be afraid to ask questions. I won´t bite...(only if you ask in french)

18-09-2007, 14:42	#225
InsaneSwede MIGWeb User Join Date: Oct 2002 Location: Sweden Drives: Astra MkI iTrader: (0) Posts: 666	The air comes into the plenum 'underneeth' the velocitytrumpets(stacks) and have no cylinder to 'favorize' it´s the same 'resistance' to all 4 runners. Almost like this: very much like cossie std plenum but more efficiant distributing of air into plenum. And then far better plenum as there are no 'flat walls' behind the trumpets, (can produce unwanted rameffect) Last edited by InsaneSwede; 18-09-2007 at 14:52.