No welding but a cool project I did. Machining.

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I decided to machine the injector pockets on my plate for my 8-71 BBC EFI Jet Boat project. I machined the blank plate a while ago with the help of a friend who has a Haas machine.All in all it came out great. I took my time, did some simple math and measured 3 times. I bought a 14mm injector pocket cutting tool from Ross machine. I am using 96 Lb Rochester style injectors. This took about 30 minutes or so to do (cut the holes in the plate). Next up fuel rail machining from Ross Machine fuel rail stock(about 45 minutes).I know some here will say why? I have always wanted to go EFI and like the looks of a Bugcatcher a top of an x-71 blower. Yes I could have built my own turbo set up with EFI and such but I want to go the blower route. I do not have too much money (less blower) into the EFI set up. Just some billet stock, fuel rail stock, and time (about 200.00). This is fun for me I must say.Here is a critical part if you want your project to be straight. Indicating the fixed jaw of the vice. I am only .0003 (that is 3 tenths of a thou.) out from one edge to the other.After Locating the edge of the part with an edgefinder I was able to use the digital readout. Here is the cutting tool ready.After doing some simple math I found the points to where to machine the holes for the injectors. Here is the first hole spacing. Notice the Y-Axis is 0000. This is the center of the plate. This should not move during the whole process.Notice the tink marks from the cutting tool in the alum. What I did was space out using the digital read out and then make sure I had my math correct.Here is the first hole cut. Checking fit up and the depth. This is critical. I had to machine, clean and check the depth a few times to where I wanted the injector to sit. I then set the Z-stop and all the other holes were all the same depth.A few minutes later and all the holes are done for one side.Flipped over the other side. Notice the angle plate acting as a "stop". This lets me keep the tool in the machine with out taking it out and finding the X and Y edges again. www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:More.Here is the plate mocked up with the injectors set in place.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Ok today I machined the fuel rails matching the numbers on the digital readout from yesterday's injector plate machining. Rails are -10AN from Ross Machine. I have to devise a way to hold the rails to injector plate. Some sort of bracket. I might use Ross machine mounts for this.Here we go. Cutting the fuel rails for the length I think they are going to be. I have never done this before and I am learning as I am going.Even though my saw blade is damn near square to the saw vice I always square my materail in the Bridgeport. It just makes it easier in the long run. This also allowed me to get the rails exactly the same length. I also calculated for some "hang-over"Another critical point to mention. The rails are round so they want to move around in the vice. You can see some square key stock I cut to hold them close to square. I finished up indicating the rails to the spindle both X and Y.The Ross Machine tool is well worth the money. I set the depth and machined away.Here they are all done except for the threaded ends. I need to mock up first to see if I need any trimming. Sweet huh.Mocking up. Damn this is cool.Sorry for the poor pic. I don't know what happened.Yup, interference as I thought. The throttle position sensor hits. I marked it and will trim it. Good thing I left some hang-over. Once I get the length to where I want I will machine them for -10AN O-ring with the O-ring boss tool from MSC$$.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:That Bridgeport is way too clean.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Nice work, thanks for sharing. Sounds like an interesting project.If you don't want to stand behind our Troops, feel free to stand in front of them.
Reply:Isn't it normal to inject the fuel into the ports so that a back fire would not be so dangerous?I would think that a volume of compressed combustable mixture that large would be asking for trouble.Not trying to be a wise cracker or anything, It's just what came to mind when I saw your set up.On the positive side, sure looks like a nice job your doing.Don't talk about it, Just do it!
Reply:Originally Posted by VicoorIsn't it normal to inject the fuel into the ports so that a back fire would not be so dangerous?Answer: Nope. Need to cool the blower with fuel.I would think that a volume of compressed combustable mixture that large would be asking for trouble.Answer:Possible but a Carb set up does the same thing. That's what the blow-off on the back of the intake is for.Not trying to be a wise cracker or anything, It's just what came to mind when I saw your set up.Answer: I guess you have not seen an Enderle Mechanical set up.On the positive side, sure looks like a nice job your doing.
Reply:Originally Posted by VicoorIsn't it normal to inject the fuel into the ports so that a back fire would not be so dangerous?Answer: Nope. Need to cool the blower with fuel.I would think that a volume of compressed combustable mixture that large would be asking for trouble.Answer:Possible but a Carb set up does the same thing. That's what the blow-off on the back of the intake is for.Not trying to be a wise cracker or anything, It's just what came to mind when I saw your set up.Answer: I guess you have not seen an Enderle Mechanical set up.On the positive side, sure looks like a nice job your doing.
Reply:Good job, I went through a similiar project to get my EFI single plane from a super victor.  Not sure if you have provisions for this or not, but you HAVE TO permanently mount the rail to the intake somehow, so it can't pull off the injectors.  Again maybe you already made provisions for this - if not you MUST do that.  Here is a shot of my motor/intake setup I made that fits under the stock vette hood.  Best Times with 434 Naturally Aspirated Vette60 - 1.261/8 -  6.37@ 107.25 MPH 1/4 - 10.08 & 134.9MPH1/4 - 9.60@144MPH
Reply:Yes I know. I am going to fabricate some mounts for the rails.Thanks.  T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:ppffffftttttt..... DRO is WEAK!!!!! just kidding! i wish we had dro at work. in fact.... i wish we had edge finders.
Reply:It was my understanding that fuel injectors shuold be angled into the forward path of the flow of air or vacuum. Are these injectors in any way fashioned so that their injection path is in a "downward" direction relative to the intake hat/supercharger?
Reply:clean and precision milling... great projectUnit in my fab shop dept:my good hand and team that trust me...A lone welder make art... a village full of welder make Miracles...
Reply:Originally Posted by EnderIt was my understanding that fuel injectors shuold be angled into the forward path of the flow of air or vacuum. Are these injectors in any way fashioned so that their injection path is in a "downward" direction relative to the intake hat/supercharger?
Reply:looks awesome! I agree with you on the injectors. Normally a draw through carb goes on top of the sc this is in effect the same thing just more tuning flexibility.
Reply:Ross machine racing, eh?  Here is a -10AN fuel rail I modeled and then madeWas fairly easy - we chamfered all the injector bungs and bore barred them so they're nice and sleek.  I made a 1/8 npt elbow fitting so I can direct feed my nitrous solenoid fuel, and then powdercoated the whole ordeal "anodize red"
Reply:Also TJ - cool trick for you - since the -10AN rail is neither fully round or fully square, it can be hard to bore out the ends for -10 AN O-ring seats and tap.  However, since the rail is mostly rounded, you can slide it down inside a lathe if your lathe has 3 clamping jaws - clamp the rail only on the rounded part and when you turn it in the lathe it spins true.  The squared part will be off center and thus unmachinable but you don't need to touch that anyway - try it out, works AWESOME for my rail.  The extrusion flexes too much to try and mill on an end mill like a bridgeport when standing it on its end.
Reply:Jon, Thanks for the tips. Unfortunately my lathe is not big enough. It is a south Bend10. The center spinder diameter is not big enough to put it through the chuck and spindle. So I am going to clamp the rail to the side of the bed of the Bpt. with a large thick angle plate. Then turn the turret, indicate the hole and then chuck up the o-ring cutter tool. After that I will tap it for the threads.   Also Jon, can you tell me how you made the rails, CNC. Got any pics of them being made. Cool.  T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:that is a cool projectChuckASME Pressure Vessel welder
Reply:How did you get that square part round?Im confused , is that two pieces welded?
Reply:ill chime in I guessthe rail portion is an extrusion from ross machine racinghttp://www.rossmachineracing.com/good company
Reply:Originally Posted by Jon KRoss machine racing, eh?  Here is a -10AN fuel rail I modeled and then madeWas fairly easy - we chamfered all the injector bungs and bore barred them so they're nice and sleek.  I made a 1/8 npt elbow fitting so I can direct feed my nitrous solenoid fuel, and then powdercoated the whole ordeal "anodize red"
Reply:my bad, I think he meant they machined the injector bungs and the ends not that they made the actual rail. I might be wrong though its still early
Reply:Nice piece, are you using down injectors in manifold as well? Also, every time I've used a lathe to work fuel rails, I've had to use a 4 jaw chuck.I used to center on the hole (live center) and clearance between fuel bungs for weight savings.Hard to get a good machine finish as there's no place for steadyrest  and deflection and chatter start happening. Just not rigid enough. Did save some weight though. Looked pretty slick too.As far as mounting the rails, I will say this... bolts must be in shear position, threads will pull out and big fire will happen.Hard lesson learned on a nitrous pro-mod years ago. Hood scoop 20' in the air and flames as tall as the scoreboard at Rockingham.Last edited by sprocketwerx; 03-15-2008 at 06:25 PM.Reason: typo