And finally, a roller coaster ride on the intake, but progress, none-the-less. I cut a foam plug for casting the plenum flange (the same day we cast the throttle pedal pad). First a test, then the actual plug.
I machined it in two halves, hot glued them together, cut a fixture plate in a scrap piece of wood, then hot glued the plug to it and cut the internal runners, while the ShopBot was still zeroed over the fixture. I simply snapped it off the fixture when that was done, and cleaned up the ends of the runners.
Then the casting process began.
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Unfortunately, this one went bust. There weren't enough sprues (pour holes) and vents, and the gases and aluminum created new cavities right out onto the shop floor.
Like a good horror movie when they show an eye opening, or a hand twitching, this glowing crucible says we live to cast another day...
