My home made boost controller progress

[milgo]

Hey everyone, im pretty new here. Just thought i would post up some pictures of what ive started doing on my car. It's a white ph1 and i have had it for 2 or 3 weeks now.

I'm an apprentice toolmaker for fords and it just so happens im working in the small machine shop at the moment. Not very busy at the moment so i get a bit of time for homework :)

First job was to make a bung for the roof. It came with an extra little arial fitted at the back. Found this quite annoying so i made up a nylon bung for it as a temporary measure until i get it filled by a body shop. Made it a slight inteference fit so it just popped in with a little push. (Not very interesting i know).

http://i79.photobucket.com/albums/j136/milgo1/DSC00278.jpg

Next job was to sort the bad wheels out. I popped to coventry to pay dave a visit and got a few bits off him including a set of ph1 wheels with centre caps and cool little locking bolts. The wheels were fairly corroded so i took them to a powder coating place near me to be smartened up. Not a top notch job but a vast improvement on the current wheels.

http://i79.photobucket.com/albums/j136/milgo1/DSC00299.jpg

The locking bolts i got off dave were quite corroded so i popped them on the lathe and gave them a tart up.

Before:

http://i79.photobucket.com/albums/j136/milgo1/DSC00291.jpg

After:

http://i79.photobucket.com/albums/j136/milgo1/DSC00292.jpg

Now the boost controller. I'm just building a sprung ball bearing manual type similar to a dawes devices one. I ordered a dawes device but then after looking into them a bit decided to give it a shot myself.

I found a RC car spring lying around and a suitable ball bearing. I obviously wanted to use some good quality materials that arnt going to rust. I got hold of some good grade aluminium and some stainless steel. The main body of the controller will be made from stainless and the adjuster screw from ally.

Here are the parts i made in my spare time over the past couple of days:

http://i79.photobucket.com/albums/j136/milgo1/DSC00304.jpg

And here is how they will sort of go together:

http://i79.photobucket.com/albums/j136/milgo1/DSC00305.jpg

Should have it almost finished by tomorrow. Then its onto engine bay cleaning , removing the manifolds etc for a good clean up.

[DaveL485]

Fantastic to see someone putting skill and initiative into something like that mate, big round of applause from me :clap: :clap:

Fancy getting me a set of those wheels done too? LOL :good:

[craig21t]

nice one mate, looking good:clap:

[milgo]

Thanks :)

Did a little bit more tonight. Was pretty fiddly making this part with some internal screw cutting. Annoyingly i had no taps with the correct pitch to match the aluminium bolt i had made. So ive had to tap it finer and will be remaking a bolt tomorrow hopefully.

http://i79.photobucket.com/albums/j136/milgo1/DSC00307.jpg

Put together:

http://i79.photobucket.com/albums/j136/milgo1/DSC00310.jpg

[DaveL485]

Let me get this straight......you're making all this from scratch?

I Think me and you need a chat :friend:

[milgo]

Yeah all made from solid bar stock lying about at work. Quite a pain to get the good materials now, used to be easier. Tons of steel about though. Heh what did you have in mind then dave?

[DaveL485]

Yeah all made from solid bar stock lying about at work. Quite a pain to get the good materials now, used to be easier. Tons of steel about though. Heh what did you have in mind then dave?

Oh, not much. Just a couple of little bits to keep you busy for the next TEN YEARS LOL

[lyn21turbo]

wheels are looking great

[shep]

Let me get this straight......you're making all this from scratch?

I Think me and you need a chat :friend:


lol

[DaveL485]

Actually mate, I wouldnt mind some adapters making to fit my NoS foggers into my manifold....basically threads that I can weld in and 1)Block off, 2)use with the foggers and 3)adjust the depth of the nozzle.

You game? Some cash/parts/whatever in it for ya :grin:

[milgo]

yeah probably up for it if i can get the materials. Depends on the sizes etc. Sure i can make them though. Give me some rough dimensions, are they a solid piece or two bits that screw together to allow the adjusting bit?

[milgo]

Pretty much there today ready for some testing :)

Just put it all together with some ptfe tape to prevent any leaks, works nicely on the old air compressor.

So today i made the two brass parts, the bolt remade with a 18x1 fine pitch thread to match that in the body and the small end cap. To fit the small end cap i popped it in the freezer for a couple of hours and then pressed it into the screw cap, i made it with an interference fit of 0.05mm. That was after putting some lapping paste on the ball bearing to grind in the seat.

Although its a bit massive im pretty chuffed with it. Its only my first one so each time i could make one smaller as i try different size springs etc.

http://i79.photobucket.com/albums/j136/milgo1/DSC00311.jpg
http://i79.photobucket.com/albums/j136/milgo1/DSC00312.jpg
http://i79.photobucket.com/albums/j136/milgo1/DSC00314.jpg

[DaveL485]

yeah probably up for it if i can get the materials. Depends on the sizes etc. Sure i can make them though. Give me some rough dimensions, are they a solid piece or two bits that screw together to allow the adjusting bit?

I Can send you the foggers if you like. And the manifold if it comes to it :love:

[milgo]

Yeah sending me some bits will probably be best. Fancy doing a drawing of what you want roughly? What should they be made from? Ally?

[joff]

wow, you've got tiny hands ;) hehehe
looks good tho mate :)

[milgo]

lol, cheers :)