BMW V8 dry sump from billet

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NickG:
I thought you meant that which is sulphuric acid, apparently h2so2 is a reduction of that, I thought it was hydrogen sulphide! No wonder I dropped a level chemistry after a year!

AdeV:
Interesting stuff chaps, thanks for all the acid comments (ho ho ho); I'm not sure what effect H2SO4 (Sulphuric acid) would have on aluminium, nor HCl (hydrochloric). The good news is, the Nitric acid (HNO3) has done very little damage to the ali (a bit of leaching which will clear when I skim the top). It was working its way through the taps, but too slowly for my liking.

Winklmj - I've heard of spark erosion, but don't know enough about them really... I'll definitely take a look at building one though, I should have enough electronics ability to do that.

Anyway.... on with the show; did a bit tonight, one of those jobs which I wouldn't have needed to do had I not buggered up the taps in the first place.... making a plug to fit the hole.

First operations were to mill a block of ali down to size, then part it off its stock:

Then I used a radius cutter to get as close to 6mm radius as possible; unfortunately, I don't have a 3mm radius cutter, so a 1/8" had to be substituted in. It's only a few thou ought, and this isn't a size critical piece.

So, once the corners were all radiused (roughly) & the burrs filed off:

It nearly fit:

And, after an hour in the freezer, and few vigorous meetings with the Plastic Hammer of Battering Things Until They Bl**dy Well Fit, it DID fit:

:D

There's a smidgeon of Loctite in there too; and tomorrow I'll drill, countersink, tap and screw the piece into the hole as well, just to make absolutely sure it doesn't come loose.

Divided he ad:
Hmmm Looks like it was meant to be there! :thumbup:

You home then?
Or did you take some work with you? :lol:

Good to see you back on it :dremel: I wanna see this car running! :poke: :poke:

Ralph.

AdeV:

--- Quote from: Divided he ad on January 12, 2011, 04:51:06 PM ---
You home then?
Or did you take some work with you? :lol:

--- End quote ---

Don't worry, I haven't forgotten that I'm supposed to be phoning you.... I just had forgotten until now! :doh:

Deffo tomorrow (not now, hungry, going home to eat...)

AdeV:
I've been :poke: again..... so, a little more progress was made today. It'll be the start of the racing season soon, this sump needs to be finished...

So, where are we at? Well, I've taken about 5mm off the top, so that the engine side is now to dimension. I've taken a couple of mm off the bottom too, although there's between 8 and 11mms more can come off there yet. I'll certainly be taking 8 off, to bring the thickness to 50mm, not sure if it's worth pursuing the extra 3mm yet - the deepest hole on the inside is about 45mm; a 2mm floor thickness doesn't leave a lot to the imagination, although it would be plenty - provided there's no accidenally extra-deep holes anywhere :zap:

So: Here's the obligatory occasional arty moody shot:

Hey, I liked it. Here's one where you can see all the warts:

I figured a trial fit on the engine might be a fun idea. It also ensures I've not over-cut anywhere when I rotate the engine through ~360 degrees. No metal-on-metal noises = A good thing. There'll be a gasket in there as well, so the innards will all clear nicely.

The pipe sticking up shows the location of the oil pump. There will be 3 of those, albeit a bit shorter than that one (only a few cms), which will plug onto spigots in the side of the sump. That part will become clear later. I also thought I'd better make sure I could actually fit those pipes in, bearing in mind the cockup I made when drilling the side entry holes. Fortunately, there's plenty of room:

So... I got to thinking about those tabs, as that's the next tricky bit of machining. And the first issue - I couldn't quite decide how far out the holes were from the side of the sump! A caliper from the centre of the hole to the edge of the sump suggested 12mm (so, with a sump width of 250mm, and the other hole the same distance away, 274mm centre-to-centre). But a steel rule reckoned 276mm from centre-to-centre (or edge-to-edge, whatever). How to resolve this 2mm dilemma?

Wax!

I broke out the waxy prototype, stuck it on the mill more-or-less straight, and decided to try the 276mm spacing (i.e. 13mm from each side):

2 holes, 276mm apart. Trial-fit on the engine:

Perfect :thumbup:

Nice one, Machinable Wax :)

More tomorrow, I hope.

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