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Old 05-15-2017, 10:58 PM   #1
CarmelValleyWRX
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Default CNC porting my throttle body.

here is a little project im messing with. bought a spare TB and started cutting on it.

opening up the inlet



"knife" edging the plate. i left .5mm to seal it off. i flipped it so only one side of each edge is milled. that way the same edge seals to the throttle body when it closes.



mock up.



i still need to 3D mill the shaft to make it sleek and slim.
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Old 05-18-2017, 08:18 AM   #2
Illicit1
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Good work. I've been thinking of doing something similar for a whole now but never got around to doing it.
Every little bit counts
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Old 05-20-2017, 02:07 AM   #3
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machined the top to use rtv to seal IACV and deleted coolant lines.



now i have over 10% more cross section aria through the bore. it should have quite a bit less drag too since its more of an airfoil and not a cylinder.
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Old 05-20-2017, 03:11 AM   #4
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Silly me doing this with files and a dremel!

Nice work!
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Old 05-20-2017, 02:40 PM   #5
CarmelValleyWRX
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it would have been faster to do it with a die grinder, but now i have all the programs set up i can do another quickly... not like i have a bunch to do though plus i have bad memories if porting the exhaust holding the die grinder for hours.
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Old 05-21-2017, 01:38 PM   #6
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How much would you charge for this particular service?
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Old 05-22-2017, 12:28 PM   #7
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Quote:
Originally Posted by wrxhard View Post
How much would you charge for this particular service?
I'm sure I could rustle up a few TBs to have this done on, if you're interested in doing a short run of them.
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Old 05-27-2017, 09:02 PM   #8
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I just finished porting and polishing my TB but this is pretty awesome especially with the knife edge on the throttle plate and the modded Shaft.

I'd be interested in a shaft and throttle plate mill if you started doing this.
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Old 05-28-2017, 09:16 PM   #9
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I had a throttle body with all those same mods by previous owner. Yours its better done but i was having a lot of issues with it sticking open after WOT pulls, its like something shrunk from the cooler air rushing in. It would stick at about 5% open and id have to edge slide off throttle pedal to get it to snap shut again. Replaced with stocker and issue is gone.
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Old 05-29-2017, 04:07 PM   #10
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Default What versions are the same mechanically?

I've done this mod by hand with good results (or should I say no ill effects?). I completely removed the upper half of the shaft and countersunk the screw heads into the butterfly plate and did similar contouring as you have done on the back side of the shaft. I tapered both front and rear edges to reduce turbulence.
What size and what year throttle body are you reworking? The versions with clip-on covers are much easier to work with. Mine are off '06 or later STi's and are 60mm diameters and covers are riveted on.
I was wondering when they stopped making that clip-cover version? There seems to be a whole range of similar looking DBW throttle bodies but do internals interchange and function the same? What year/models could I look for that use that cover style, yet has the same mechanical and electrical functionality as later riveted on cover models?
Various part numbers look similar but are they?:
03?,04, 05, Impreza WRX STI BAJA FORESTER, 05-06 LEGACY. SAAB 9-2X PNs. 16112AA110 or 16112AA090. Possibly 16112AA010 or 16112AA020?

Any clarification on similarity of size and functionality would be appreciated.
Is there a larger Subaru DBW throttle body than 60mm?
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Old 06-21-2017, 09:14 PM   #11
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Looks like jewelry!
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Old 07-06-2017, 10:09 PM   #12
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HAHAHA love it!!!

I'm an engineNerd and am finally looking into building my own CNC. I foresee many similar projects coming out of my garage.
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Old 07-07-2017, 10:21 AM   #13
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Quote:
Originally Posted by Homemade WRX View Post
HAHAHA love it!!!

I'm an engineNerd and am finally looking into building my own CNC. I foresee many similar projects coming out of my garage.
You should! Or just buy a five axis? Pistons, heads... Watched Kenny (at Larry's) run their five axis CNC mill as it ported Subie heads. Takes all the fun out of hand porting guesswork.
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Old 07-07-2017, 03:18 PM   #14
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Quote:
Originally Posted by no694terry View Post
I had a throttle body with all those same mods by previous owner. Yours its better done but i was having a lot of issues with it sticking open after WOT pulls, its like something shrunk from the cooler air rushing in. It would stick at about 5% open and id have to edge slide off throttle pedal to get it to snap shut again. Replaced with stocker and issue is gone.
there is a bearing which centers the shaft and it needs to be carefully aligned. also there is a dry molly coating that comes on the throttle body that most people clean off. i sprayed a new coat of molly on mine and it is like new.

Quote:
Originally Posted by Scargod View Post
I've done this mod by hand with good results (or should I say no ill effects?). I completely removed the upper half of the shaft and countersunk the screw heads into the butterfly plate and did similar contouring as you have done on the back side of the shaft. I tapered both front and rear edges to reduce turbulence.
What size and what year throttle body are you reworking? The versions with clip-on covers are much easier to work with. Mine are off '06 or later STi's and are 60mm diameters and covers are riveted on.
I was wondering when they stopped making that clip-cover version? There seems to be a whole range of similar looking DBW throttle bodies but do internals interchange and function the same? What year/models could I look for that use that cover style, yet has the same mechanical and electrical functionality as later riveted on cover models?
Various part numbers look similar but are they?:
03?,04, 05, Impreza WRX STI BAJA FORESTER, 05-06 LEGACY. SAAB 9-2X PNs. 16112AA110 or 16112AA090. Possibly 16112AA010 or 16112AA020?

Any clarification on similarity of size and functionality would be appreciated.
Is there a larger Subaru DBW throttle body than 60mm?
im doing 2002-2005 wrx TB which is cable pull. i heard there is some Acura or lexus TB that works on the sti.

Quote:
Originally Posted by Homemade WRX View Post
HAHAHA love it!!!

I'm an engineNerd and am finally looking into building my own CNC. I foresee many similar projects coming out of my garage.
yep its super handy but it takes many years to get good at it. i have been doing it for 5 years for fun and semi professionally and still feel like i barely know what im doing sometimes. its a whole different way of thinking compared to most things. like a puzzle.

Quote:
Originally Posted by Scargod View Post
You should! Or just buy a five axis? Pistons, heads... Watched Kenny (at Larry's) run their five axis CNC mill as it ported Subie heads. Takes all the fun out of hand porting guesswork.
just buy a 5 axis... maybe start out with a 3d printer.

you can do pistons on a 3 axis or a 3+1 or 3+2 axis method easily. heads could probably be done in two setups on a 3 axis and save some coin for a DIY ( $500,000 -$1,000,000).




i am now running my stock throttle body again because i ported it also. this one in the pix is just sitting around...

Last edited by CarmelValleyWRX; 07-07-2017 at 03:28 PM.
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Old 07-07-2017, 09:03 PM   #15
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Well aware. I have manual and cnc experience. More so I'm used to designing so interesting race engine bits as a design engineer....who worked very closely with the best machinists I've ever met.
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Old 07-08-2017, 11:29 AM   #16
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Quote:
Originally Posted by Homemade WRX View Post
Well aware. I have manual and cnc experience. More so I'm used to designing so interesting race engine bits as a design engineer....who worked very closely with the best machinists I've ever met.
The breed of machinist are going away and bringing in operators, it took me a year to find a guy who could indicate a hole lol

I wish I could get pics of some of the engine parts I make off the f35, using a 6in ooh 3/8 endmill to get into a 1/2in port and clean up all the journals at 25000rpm and our feed rate is pretty much a 100% rapid movment.

I did a few Honda heads on a 3 axis and id bore on the blocks. I miss working at my old shop but now I'm the aerospace So I'm picking up new tricks and trades.
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Old 08-27-2018, 10:04 PM   #17
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Just picked up my Grizzly G0704 doing the Hoss conversion to get my feet wet on making my own CNC.

You done anything fun lately?
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Old 08-30-2018, 11:43 AM   #18
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^what do you mean by 'making' a CNC?

Like you are going to retrofit encoders on ballscrews and build a cnc control unit?
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Old 08-30-2018, 01:25 PM   #19
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^what do you mean by 'making' a CNC?

Like you are going to retrofit encoders on ballscrews and build a cnc control unit?
That's the one. Have the power supply, control boards, stepper motors, etc...ball screws will be later. Keeping the ACME stuff for now just to get it running.
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Old 08-30-2018, 02:42 PM   #20
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Are you just interested in doing all that electronics work because you enjoy it and don't care about the money?

Just curious because despite the cost of new cnc's, used ones can be gotten at auctions or from shop closings for literally pennies on the dollar.
Like a couple grand will get you a cnc that functions totally fine. It will be 20+ years old but will still work great.
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Old 09-04-2018, 01:53 PM   #21
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Are you just interested in doing all that electronics work because you enjoy it and don't care about the money?

Just curious because despite the cost of new cnc's, used ones can be gotten at auctions or from shop closings for literally pennies on the dollar.
Like a couple grand will get you a cnc that functions totally fine. It will be 20+ years old but will still work great.
More than well aware of what potentially clapped out industrial CNC's sell for and the costs of a having a rigging company handle and deliver them.

For me right now it's more initial cost. The whole thing is $2k, and gets my feet wet with some of the non-professional CAM and CNC controllers. Also, when a part breaks, as they inevitably do with CNC's, getting a replacement part is cheap and easy.

The bigger issue for me is a lack of space between my cars, parts shelves, tool boxes, work bench, welding kart and table....space is tight at the house. I still have a 2'x4'x8" router/plasma table in here too. I'll be finishing up the Z-axis automation with the mill.
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Old 09-04-2018, 03:29 PM   #22
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Quote:
Originally Posted by rtv900 View Post
Are you just interested in doing all that electronics work because you enjoy it and don't care about the money?

Just curious because despite the cost of new cnc's, used ones can be gotten at auctions or from shop closings for literally pennies on the dollar.
Like a couple grand will get you a cnc that functions totally fine. It will be 20+ years old but will still work great.
the last CNC i got rid of, i was offering FOR FREE if someone paid the riggers to take it out of my shop. it was in decent working condition and under power, but we didn't get a single bite. it was an 80's Ooya RE-1M with a Fanuc 6m control and CAT45 3500 RPM spindle. bummer to see it go to scrap, but it had to go to make room for a used Haas VF3.
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Old 09-05-2018, 10:31 AM   #23
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^totally, that's pretty much why their value used is virtually nothing for mid sized or larger stuff

and after they are moved it's basically guaranteed a board or something will have been damaged in the process and need control work

Last edited by rtv900; 09-05-2018 at 10:37 AM.
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Old 09-05-2018, 10:36 AM   #24
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Originally Posted by Homemade WRX View Post
clapped out industrial CNC's
clapped out aye?
that sounds familiar.
The last clapped out 30 year old machine I got cost 1 grand and holds +/- .0001 consistently, no riggers needed either, I loaded it with a forklift and hauled it on a trailer. Granted it's a lathe not a mill though.

Clapped out or not, a machine that easily holds the tolerances you need for almost no money still gets a job done at the end of the day.
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Old 09-05-2018, 02:19 PM   #25
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Don't get me wrong, I've seen plenty clapped out and then there are plenty that are just old and people don't want them.

Before I bought this, I missed out on an old MHP 4-axis running Moog Hydrapath

Not against them, but again, cost and space in my garage is the real issue. I'd have found room for that 4-axis machine though!!

I had really wanted the MV40 that we sold at Roush Yates when Haas came over to Ford. That thing went for dirt cheap. I would literally stick through the ceiling of my garage though.
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