Lets continue, making the twin throttle body intake elbow for 4.2L, 4.7L and 4.9L Kenne Bell superchargers.
After internet search couldnt find 5" thin wall 90 degree elbow with 1 r (5" this case) radius. So need to make some.
First draw a simple hammer form in Fusion 360, holes at the ends are for vise grips, hold the plane down. Use pieces of rubber hoses at noses of the pliers, dont make the panel.
Then 3D printed it out of plain PLA and started anneailing 2mm aluminium with sharpie and propane torch.
When you have burned the sharpie off, the aluminium is soft. Depends how much you shape it, you may need to redo the annealing.
After shaping with plastic slapper and shrinking I had four halfs done. Time to get them fit the machined flance, used machinest square and laser to determine where to cut the overlapping parts off.
Next task make mounting tool for the flance and bold it tight so it dosent deform under welding. To keep it straight. Tig-welded the halfs together and I also machined flance with O-ring groove for 102mm LS throttle body. Those got welded to open ends of the eblows.
After all was welded, I spend some time to file the seams and slapped them all smooth. I took it to work, machined mounting surface to our vertical milling machine and squared the TB flances, also the special flance in the middle. more that later..
That kind of vertical mill is powerful tool to have. Work area is measured in meters (feets), Table can be turned in one thousands of degree (0.001') or -millimeters. Just get your bearings with 3D measuring tool..
This kind of job is easy for this kind of machine, just turn the table 180 degree and you get both size parallel to each other with same mounting. Or 90 and machine the face of the middle flance. Everything it parallel and square and straight. Even machined the main flance straight as last task with another set up.
So lets get to back the square flance in the middle. I did re-machined that O-ring groove again. Thats how much it shrank in welding.
Anybody want to guess what is for?
Something outside of the box..again..
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