SY2932
Administrator
When I buffed my upper intake and intercooler this past summer, I ditched the ill fitting block off plate that a good friend gave me several years ago. It performed flawlessly but there was no way that it was going back into service after all the time that I spent finishing the top of my motor. I got the hole dimensions off the intake and saw cut a piece that was then sanded to match it:
Another project that I am working on would make it impractical to sand it to match so, I spent some time doing the CAD/CAM & CNC thing after work.
This is the exact block off plate that I was running in the past. I "painted" the boss on the intake wih a black magic marker to show how well these "generic" block off plates actually *fit*.
And from the other side.
Here's mine.
And the other side.
The material is aluminum decked perfectly flat (plus minus zero). The holes for the stainless steel flat head screws are drilled for .010" clearance. The plate is also countersunk so that when the screws are tightened, they locate the plate directly over the holes. The perimeter was cut with a tapered end mill to match the draft angle on the intake boss as well.
It took several test cuts to get the geometry dialed in but in the end, it was worth it.
One member has been my "test mule" since I couldn't test it to my intake due to it not being factory anymore. I also have a brass plug in my upper intake preventing exhaust gas from getting to where my plate is. I asked him to try the plate without a gasket or RTV since that is what I had in mind when I designed it. No leaks and I got a
on the fit. One project down, many more to go...
Another project that I am working on would make it impractical to sand it to match so, I spent some time doing the CAD/CAM & CNC thing after work.
This is the exact block off plate that I was running in the past. I "painted" the boss on the intake wih a black magic marker to show how well these "generic" block off plates actually *fit*.
And from the other side.
Here's mine.
And the other side.
The material is aluminum decked perfectly flat (plus minus zero). The holes for the stainless steel flat head screws are drilled for .010" clearance. The plate is also countersunk so that when the screws are tightened, they locate the plate directly over the holes. The perimeter was cut with a tapered end mill to match the draft angle on the intake boss as well.
It took several test cuts to get the geometry dialed in but in the end, it was worth it.
One member has been my "test mule" since I couldn't test it to my intake due to it not being factory anymore. I also have a brass plug in my upper intake preventing exhaust gas from getting to where my plate is. I asked him to try the plate without a gasket or RTV since that is what I had in mind when I designed it. No leaks and I got a
! Unfortunately at this time I have no intention of selling these due to the fact that I do not own the equipment that they are being cut on. All of our CNC mills cut molds for fortune 500 companies so, open machine time is both rare and expensive. My boss has no problem with small personal items but he may frown on me making parts for capital gain. I will talk to him about it later today when he returns to the plant. On the other hand, if you are willing to pay the standard going rate of $100 an hour for machine time, I'm sure I could get ya something...
