Solex 40Pl Intake manifolds
 

We have a few sets of Solex manifolds in very poor condition and need replacements.

These manifolds are increasingly scarce and costly.

http://i197.photobucket.com/albums/a...psnvcb4zz3.jpg

W have just finished making the basic pattern equipment and will be fitting them to boards and adding the running system next week.

We will make initial parts in Aluminium and once they are proven we will make them in AZ91 Magnesium Alloy.

Very cool!

Cool but why mag?
It was a PITA from the factory...plus they were painted black so who would know the difference.

Solex manifolds were never painted black they had a chromate finish that was slightly iridescent.

The finish is very difficult to reproduce but Aluminium will be nothing like the same.

http://i197.photobucket.com/albums/a...psutsjcoih.jpg

I can't buy a suitable chromate solution here in Europe but I think there is one available in Texas but shipping is a real nightmare.

http://crestchemicals.com/pdf/mag_CC_TD_2015.pdf

I used to visit Fort Worth regularly but haven't been for a few years and Airport security is a real nightmare now.

I want to reproduce manifolds as closely as possible hence the AZ91.

Hey Chris, how were those patterns made? CNC timber or cast polyurethane? Would you mind posting some larger images?

Thanks,

Rob

They are straightforward 'wooden' patterns made using very traditional pattern making skills.

The have been made to allow the use of green sand and the prototypes will be made using this technique.

The pattern is split so each half can me mounted on a 'parting' board which will allow control of the running system once we have made prototypes.

The pattern not only splits vertically but needs to split horizontally to allow the detail of the upper surface of the intake manifold to be made correctly.

We could have made these patterns from a CNC scan and then 5-Axis machined pattern board but they would have been much more expensive.

We will cast the production manifolds using an Air Set technique which will provide better dimensional control and surface finish compared to green sand.

Understand. Thanks for the information Chris.

Those also look like core boxes in your picture, I presume you use a core for the centre of each manifold runner?

The 2 x boxes on the left are for the fuel reservoir mounting detail.

The single box on the right is the core box.

We will use a 'cold box' core for these manifolds as volumes are low and the technology of core making has improved greatly in recent years so we can avoid the costs associated with a 'hot box' core.

There is only a single core needed as the central core only needs to be positioned at a slight angle for this manifold.

The 911R manifolds we made earlier this year had 2 x core boxes as the outer runner was a much more complex shape.

The 'print' for the core is the part of the pattern that is painted black.

http://i197.photobucket.com/albums/a...psxdguoyvl.jpg

First castings are completed and will be machined next week.

We will make any small mods that maybe needed and then try Magnesium.