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    Thread: Single sidedraft manifold, something a little different.

    1. 06-04-2009 10:39 AM #1
      We needed a single sidedraft manifold for a cross flow head, nobody we know of makes them commercially so I decided to make one. What make this different is I decided to cast it, something I don't recall seeing on this forum before. This is my VERY first attempt as sand casting anything and as such I'm fairly pleased with the results, the size and shape are spot on what I'd planned but the surface finish on the casting leaves a lot to be desired. For me, this was an experiment, I learned a lot in the process of doing this, I think my next casting, if there is one, will be look much nicer. Here are a couple of pics, one fresh out of the sand and one after a little bit of clean up;





      Modified by ABA Scirocco at 5:50 PM 4-10-2010

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    3. Member fastmaxxcooper's Avatar
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      06-04-2009 09:05 PM #2
      i'm pretty impressed. with some machining and some grinding it should be very nice looking

    4. Member turbinepowered's Avatar
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      06-04-2009 09:45 PM #3
      Did you do "lost foam" plug casting for that?
      Looks good!
      Quote Originally Posted by zukiphile View Post
      There is an area of a normal brain that lets the owner know the object works and needs to be left alone. Not all of us have it. It is like being colorblind.

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    6. 06-04-2009 10:11 PM #4
      Quote, originally posted by turbinepowered »
      Did you do "lost foam" plug casting for that?
      Looks good!

      No, conventional sand casting with a pattern and core. Here's what the mold and core looked like just before it was closed for pouring.





      Modified by ABA Scirocco at 5:52 PM 4-10-2010

    7. 06-04-2009 11:02 PM #5
      sick, it looks better than some of the stuff out of china on ebay,, ,
      Coming soon. A new fab shop Im me for info

      Meriden Fire IAFF local 1148

    8. 06-04-2009 11:46 PM #6
      how did you get the inside to be hollow?

    9. 06-04-2009 11:56 PM #7
      There's sand core inside the mold to make the hollow spaces, you can see it sitting inside the mold in my last post.

    10. 06-05-2009 05:23 AM #8
      awesome, my father cast original mag wheels back in the late 60's

    11. 06-05-2009 11:27 AM #9
      yeah, but I can't figure out how it stays supported. It would be sand just supported on the edges and i don't know that stands up, right?
      Is the sand that sticky?

      btw, great to see someone willing to do something different!

    12. 06-05-2009 12:38 PM #10
      The sand in the main body of the mold is mixed with a little clay so it sticky to itself and will hold a shape kind of like the sand in a sand castle. The sand for the core is mixed with a binder that sets up like glue, the core is rock hard.



      Modified by ABA Scirocco at 12:55 PM 6-5-2009

    13. Member Turbo_Pumpkin's Avatar
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      06-05-2009 12:50 PM #11
      Very cool!
      HomeGrown Motorsports

    14. 06-05-2009 03:52 PM #12
      What do you plan to do to face the flanges?
      Are you going to have them milled or do you plan on lapping them by hand against something like glass?

      Did you happen to find Dan's Workshop website when researching this?

    15. 06-05-2009 04:38 PM #13
      I expect they'll get milled but I'm not sure. I've pasted the casting on to the guy I made it for and I'm leaving those details to him. He's got the necessary equipment milling machines, surface grinders etc, he'll do what he thinks is best. He'll probably do it some time next week, after this weekend, there's a two week break in his racing schedule and he'd like get some dyno testing in during the break.
      And yes I've seen Dan's site, I've looked at a ton of different metal casting sites including Dan's workshop.

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      06-10-2009 10:29 AM #14
      This is awesome.
      I was just thinking the other day, how it would be nice to make sand cast manifolds to try out different intake designs.
      How much does something like this cost?
      Did you melt and pour the aluminum yourself, or bring it somewhere to be done?
      Where could I find someone who can do this? IE: Is this a backyard business, or some sort of rare profession to find?
      Thanks in advance!


      Modified by Jettaboy1884 at 11:32 AM 6-10-2009

    17. 06-10-2009 12:02 PM #15
      I did everything except the finish machining myself, patternmaking, mold making melting and pouring. I'm into this manifold for about $200+ but that includes stuff like my furnace and sand that I'll be able to reuse on other projects, the next project I do will cost probably a quarter of that.
      There are foundries that will do small one off projects, I went and visited one near Toronto earlier this year, it was very educational. I'm not quite sure how you'd go about finding a friendly foundry in your area. It's not unusual for people working on antique boats to have reproductions of stuff cast so maybe go down to the maintenance area of a local yacht club and ask around, indirectly, that's how I found the one I visited.


      Modified by ABA Scirocco at 12:03 PM 6-10-2009

    18. 06-10-2009 03:22 PM #16
      Did you use a gas or electric furnace?
      What did you use for your aluminum?

    19. 06-10-2009 05:02 PM #17
      I used a big home made propane torch to melt it and the aluminium came for a VW alloy rim. I just cast a second one, I'm starting to get a handle on the surface finish issue, the latest one looks WAY better than the first.


      Modified by ABA Scirocco at 5:04 PM 6-10-2009

    20. 06-10-2009 05:56 PM #18
      That is sick man.
      I helped out with a senior design team that made some cast parts for our SAE Baja cars.


    21. 06-11-2009 01:53 AM #19
      I want to try this but I need another hobby like I need a hole in the head.
      Are those transmission cases or something?
      What was the solution to your surface finish issues?


      Modified by jackfrost1031 at 1:58 AM 6-11-2009

    22. 06-11-2009 10:01 AM #20
      It seems the first casting was poured too hot, a cooler pour made a huge difference.

    23. 06-11-2009 11:37 PM #21
      Very very very cool.

    24. Member GTijoejoe's Avatar
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      06-14-2009 12:35 PM #22
      Pretty sweet [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      2.0T+034efi+meth = 300+whp = RIP

      Quote Originally Posted by Ryukein View Post
      Everyone always praises function over form until the form is something that they don't like

    25. 06-14-2009 01:27 PM #23
      I'll put up another picture or two after it's been machined, hopefully that'll happen over the next few days.

    26. 06-20-2009 02:05 PM #24
      Haven't seen something this interesting on the VWVortex in a long, long time.
      That is really really cool. A long lost art. I would LOVE to see pics of it all cleaned up and machined.
      I'm also unclear as to how you sperate the core sand from the outside sand.
      Thanks for posting! [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Markku Kivinen | Agtronic Motorsport

    27. 06-20-2009 03:23 PM #25
      Thanks Markku, given what I've seen of your work, that's high praise indeed.
      Anyways, the core is made separately and of a different sand than the main body of the mold. The main body is made with the pattern inside, the mold is then opened up and the pattern removed and the core placed inside (see my 3rd pic) then the mold is closed up for pouring. After the pour, the main body of the mold open up and that sand is very easily cleaned off but at that point, as you can see in my first pic, the core sand is still inside the manifold, it's quite hard and requires modest force to remove. Here's a picture of the core and the mold used to make it. It also shows very clearly the internal shape of the manifold.


      BTW, I talked to my buddy that now has the manifold, he's just finished machining it and tried it on the car for the first time today. He says that with the short runners and small plenum, the throttle response is amazing and it sounds really mean, I wish I'd been there. Unfortunately, it'll be 2 or 3 days before I'll able to check it out in person but when I do, I'll take a few more pictures and maybe even a short video and post them up.

      Modified by ABA Scirocco at 8:50 AM 11-14-2009


      Modified by ABA Scirocco at 5:53 PM 4-10-2010

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