BMW V8 dry sump from billet

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AdeV:
OK, so I did a bit more on this yesterday afternoon, after the GP qualifying.. First job was to mill off the end of the plugs, so I would have a nice flat plate again:

First cuts, with a ripper, took me to within 0.5mm of flat:

The final 0.5mm was taken with a regular end mill. Looks like I overshot by a tiny amount:

The next job is to drill the cross-holes; these will bring the oil flow out to the side of the sump. The setup is "interesting" to say the least:

Lucky I never finished that taper adapter clamp for the lathe, as here it is helping to hold the sump down :lol:

Final photo for today, I centre-drilled the three holes:

No pics, but I then drilled the short (85mm) hole with a 5mm, 10mm and finally a 5/8" drill. Repeated for the 2nd hole (105mm). Unfortunately, drilling through the plug, the 5/8" drill knocked the piece that's supposed to separate the two holes, out of place :(

Therefore, plan "B" will now occur: I'll have to drill into the plugs from the underside, between the side holes, tap them & insert a bolt. That won't prevent them from unsticking when drilled, but it should stop the plug portion from wandering out of the hole. So long as the outer plugs stay firmly glued up, I can live with it I think. More later... after the GP.

AdeV:
Disaster Averted.....
...or, On The Importance Of Taking Notes

I don't know when I made the mistake. Probably on Saturday, seeing as I didn't do anything on Sunday. Or maybe it was when I made the plugs. I will never know...

Having glued the plugs in the other week, it occurred to me I hadn't made a note of how long they were. After some head-scratching, a plan was hatched. I shoved a piece of welding rod down each hole, and marked it where it met a convenient rib. By withdrawing the rod & laying it flat on the sump, I could see the end point & mark/measure accordingly. The plugs ended 20mm, 50mm and 80mm deep as applicable. Great, says I, and made the above centre drills at 20, 50 & 80mm. I then drilled the 50 & 80mm holes... because they were the shorter (& thus easier) ones to do.

By random good fortune, I didn't drill the 3rd hole, instead I went out and had tea in a pub in Wales...

Today, I drew up those holes on my Visio master plan set - and discovered that the 20mm hole (which is ~16mm in diameter, and therefore would be around 12mm from the front edge of the sump) would, in fact, foul the mounting holes (which are drilled all the way through the block - those being 6mm in diameter & 9.5mm in from the edge; a 0.5mm overlap...) This would have holed the front of the sump, causing all kinds of mayhem and annoyance....

The solution is not elegant, but as I've already drilled two of the holes, is the only one open to me: I've moved the hole inboard by 3mm; thus providing 2.5mm clearance from the mounting hole, which should be plenty. In hindsight, the cross-holes should have been a further 8mm inboard; as it is I've centered the drill on the end of the plugs, instead of measuring to "just miss" the end of each one - which would have been a far better solution.

Still, at least I didn't scrap the sump. A close shave, that one...

Stilldrillin:

--- Quote from: AdeV on July 26, 2010, 07:50:47 PM ---
Still, at least I didn't scrap the sump. A close shave, that one...

--- End quote ---

By `ek Ade! :bugeye:

THAT mustn`t happen now.......

Wishing you Good Luck, and clear thinking, from now on....... :thumbup:

David D

Divided he ad:
Sounds like lots of fun there Ade :coffee: :smart: :doh: :thumbup: is how I see it in smileys :)

Very happy you didn't lose it this far in :clap:

As David said "Wishing you Good Luck, and clear thinking, from now on....... :thumbup: " :med:

Ralph.

AdeV:
Just a quick update: I'm still dissolving the taps away... they're taking their sweet time. After syringing in a little conc nitric acid, and waiting 24 hours:

Clean away the brown snot, re-load with acid, wait another 24h, rinse & repeat...

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