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03-04-2011, 02:51 AM | #1 |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
Custom Machining Limits?
So I'm just getting into my new major (2 years of Civil Engineering under my belt), I'm now in Manufacturing Engineering. To date we are doing a lot of manual machining and are working our way into CNC work as well.
Now I'm always looking for a fun project for my car. Something to create weather it be unique by function or unique by look. Either way, what are the limits of a machinist in a general machine shop? Things I see not being a problem: - Shifters - Shifter Assembly (have a prototype made up right now) - Battery tie down - Lug nuts (CNC program?) Things I'm not 100% on: - Engine Pitch Mount - Rotors (as long within tolerance, of proper material, to target Rockwell) - Endlinks - Other Some things just seem obvious, like I know I will never be able to build a proper gear set for my transmission, or whatever else that would require extreme precision. Mostly I just want to hear what machine work you have done for your car. If some of the items I listed should never be machined without all the proper tools let me know, I'm just kinda trying to see what I can attempt to build while the metal is free and the lab is basically open all day
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03-04-2011, 02:03 PM | #2 |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
So nobody machines parts for their car? haha
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03-04-2011, 02:07 PM | #3 |
Scooby Guru
Member#: 79643
Join Date: Jan 2005
Chapter/Region:
NESIC
Location: The internet
Vehicle:2021 STI TE Terminal black pearl |
I used a dremel to carve out a radiator shroud, does that count?
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03-04-2011, 02:57 PM | #4 |
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Member#: 22035
Join Date: Jul 2002
Chapter/Region:
SCIC
Location: San Diego, CA
Vehicle:2014 Brocoma DCab 71 FJ40, 13 DRZ400SM |
depends on the cnc. you talking mill or lathe? also, you say a shifter is no prob, but not an endlink or pitch mount? those two would be much easier then a shifter.
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03-04-2011, 05:00 PM | #5 | |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
Quote:
The reason I class the pitch mount and endlinks as not sure is I am thinking about potential loads, tension, torsion, element abuse, etc. A shifter/shifter assembly is used to change gears from inside a car. It's not dealing with rain, snow mud, its not under extreme amounts of force, it just sits there. I really don't know what kinds of loads each endlinks and pitch mounts undergo but if its small enough of a load and with the right metal, design, and rockwell I can get it to work they sure I'll give them a shot. This is a glimpse of about 1/4 of the machine shop, its big for a school machine shop! |
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03-04-2011, 05:08 PM | #6 |
Scooby Specialist
Member#: 44762
Join Date: Oct 2003
Chapter/Region:
MWSOC
Location: Palo, IA
Vehicle:2013 BRZ WRB |
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03-04-2011, 05:32 PM | #7 | |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
Quote:
For like the endlinks, I hear how Kartboy are tops, whiteline are "eh" and its like, you would think a design as simple as 2 holes and a connecting portion between them would be simple enough but obviously those slight variations in design are what make the difference. |
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03-04-2011, 06:26 PM | #8 |
Scooby Specialist
Member#: 44762
Join Date: Oct 2003
Chapter/Region:
MWSOC
Location: Palo, IA
Vehicle:2013 BRZ WRB |
Are you talking about front endlinks? Yeah, couldn't be much more simple. Not really much to "machine," a piece of aluminum or stainless or even painted mild steel with a couple holes drilled to push bearings in to.
Here are my DIY rear endlinks: |
03-05-2011, 09:42 PM | #9 |
Scooby Specialist
Member#: 206720
Join Date: Mar 2009
Chapter/Region:
SWIC
Location: Albuquerque NM
Vehicle:2002 WRX Wagon Silver |
Start off by making a license plate delete. Next I would make some underbody braces. Maybe an x-brace.
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03-05-2011, 10:30 PM | #10 |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
I might actually try the license plate delete and battery tie down. I want to have it say something and was waiting to learn EDM first but I think with a 1/4" end mill and dept of cut of .100" I should be able to execute a simple "WRX" wording...
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03-05-2011, 11:03 PM | #11 |
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Member#: 104878
Join Date: Jan 2006
Chapter/Region:
TXIC
Location: copperas cove
Vehicle:02 wrxbastardchild aw, MPS 2.34 breaking in |
how about machining a set of tgv deletes that are all smooth and sexy on the outside with only ports for the injectors and mounts for your own fuel rails?
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03-05-2011, 11:53 PM | #12 |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
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03-05-2011, 11:58 PM | #13 |
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Member#: 164242
Join Date: Nov 2007
Chapter/Region:
E. Canada
Location: Toronto
Vehicle:1992 SVX 2008 Spec B |
Pitch-mounts and endlinks would be cake. You could come up with something real nifty if you were using some CAD/CAM software to generate the machine paths, but even with manual G-code it wouldn't be hard to make the basic item, even with some decorative ribs.
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03-06-2011, 12:19 AM | #14 |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
Yeah I have a free student version of AutoCAD and am getting some Solidworks from the school. If I can design something simple enough and write the code I could run some prototypes and if all works out sell a few away...just not on here :/
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03-06-2011, 12:55 PM | #15 |
Scooby Guru
Member#: 104878
Join Date: Jan 2006
Chapter/Region:
TXIC
Location: copperas cove
Vehicle:02 wrxbastardchild aw, MPS 2.34 breaking in |
you can get tgvs and a manifold for cheap on the forums, then get all your measurments.
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03-06-2011, 02:07 PM | #16 |
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Member#: 256615
Join Date: Sep 2010
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i wouldnt get too deep into machining the tgvs.......they are crap casting with pitting and holes throughout.
Now machining your own intake flanges for a manifold or your own billet tgv setup is a different story. |
03-06-2011, 02:40 PM | #17 |
Scooby Specialist
Member#: 44762
Join Date: Oct 2003
Chapter/Region:
MWSOC
Location: Palo, IA
Vehicle:2013 BRZ WRB |
I didn't see any pitting in my TGVs. I don't know what aluminum ingots cost but IMO custom machined TGVs would be a huge waste of money.
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03-06-2011, 02:47 PM | #18 |
Scooby Specialist
Member#: 150289
Join Date: May 2007
Chapter/Region:
SWIC
Location: PHX, AZ
Vehicle:2006 SV650, 05 CTSV 1972 Travelall |
wow, you guys have a big shop. The manual shop at my school is about 1/8th of that.
All of that stuff you can do on a manual machine. You'll want to use a CNC machine if you start making parts with radii on the contours and such. Make your endlinks out of aluminum. I wouldn't make rotors. Lug nuts would be a pain on a manual machine. CNC opens lots of doors that take hours and hours of different setups on a manual machine. |
03-06-2011, 02:55 PM | #19 | |
Scooby Specialist
Member#: 219426
Join Date: Aug 2009
Chapter/Region:
MAIC
Location: Memphis, TN
Vehicle:2004 Subaru WRX WRB Stage II |
Quote:
-Over 30 manual mills - Between 25-30 manual lathes - Around 8 wire EDM Machines - in that shop 3 CNC mills - 4 CNC lathes - Heat treatment room - Full metrology lab - Then we have another lab that is strictly CNC mills and all the hydraulic robotics. - And FREE metal (They encourage custom work and practice, so I can get myself a set of endlinks or whatever for free! ) I want to try to make some of the parts on both to start, since I love manual machining but at the same time am trying to grasp simple G/M codes on the CNC. The lug nuts I wanted to make out of a lathe CNC script, simple thread and some exterior design. |
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03-06-2011, 11:39 PM | #20 |
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Join Date: Jan 2006
Chapter/Region:
RMIC
Location: Pittsburgh
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Lug Nuts. Think about making a set with a matching Key. Truly a set of LOCKING lugs for sure.
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03-07-2011, 01:40 AM | #21 | |
Scooby Specialist
Member#: 150289
Join Date: May 2007
Chapter/Region:
SWIC
Location: PHX, AZ
Vehicle:2006 SV650, 05 CTSV 1972 Travelall |
Quote:
Just seems like more work than it's worth. Good for you though if you can make it work. |
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03-07-2011, 09:05 AM | #22 |
Scooby Specialist
Member#: 256615
Join Date: Sep 2010
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03-07-2011, 09:53 AM | #23 |
Scooby Specialist
Member#: 44762
Join Date: Oct 2003
Chapter/Region:
MWSOC
Location: Palo, IA
Vehicle:2013 BRZ WRB |
I ported mine, didn't see any problem. Maybe I got lucky. I really think, even if they do have pits, they're good enough because aluminum is expensive. But since he's getting it for free, why not.
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03-23-2011, 09:45 PM | #24 |
Scooby Newbie
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Join Date: Mar 2010
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MWSOC
Location: Cedar Rapids, IA
Vehicle:2007 Impreza WRX/TR White |
Battery Tie downs would be quick and easy.. If your wanting to engrave something on the top i would recommend using a 90deg. Engraving Tool. Looks much better than a end mill buried into the material. Usually drop it down about .015-.020 and let it eat! Just do the outlines of the letters instead of the entire letter. Can produce sharp corners and clean lines with no cutter marks.
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03-24-2011, 09:26 AM | #25 |
Scooby Specialist
Member#: 88976
Join Date: Jun 2005
Chapter/Region:
NESIC
Location: Hinesburg VT
Vehicle:Main Ingredients: WRX motor, PPG's, me |
If you have access to a waterjet, make use of every minute you can get on it. They're awesome.
Heres a few thing I've made with one... Other things you could make... camber plates with dust guards Adjustable lateral links Trailing arms A arm mounts (anti-lift kit) Catch can with a well thought out mount, (no zip ties or just hanging by hoses!) Shifter Coolant overflow tank Skid plate Something I've always thought would be cool would be a reinforced jack point or just additional points. Could be bolt on or welded. I always find myself wishing I had a couple more options for where to rest my car on while I'm working on it. |
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