custom throttle body

[krymis]

I have bobcad v21 for cad cam, mach 3 for interpretur, and a few machines i can use. I want to make an aluminum throttle body for a turbo project i am building. The setup is a 2.0L engine being stroked to a 2.3. I made a custom intake but wanted a custom 70-75mm throttle body to go with the intake. Can anybody help me get designing and machining a prototype. I will be machining it out of tooling board before using the aluminum. I want to make the butterfly and shafts and all. Where do i start. I want a 3-3.5 inch opening and the intercooler end caps and piping will be sized to what ever size the throttle body is. I have a prototype 3 inch maf made with my polymer setup.

Hey this sounds like fun!!!!!!!!

First you need to post some kind of Picture of what we are looking at.

Second, This is going to require a lot of Homework on your end beacuse of the Clearances and Area around the Throttle Body.

Third, you will have to do more Research on the Volume of CFM, Travels of the Throttle Body and Geometry. (Remember too much air without the Proper Ventry Design Could Be a Really Bad Thing)

Fourth, All of your Piping will have to be able to snake around the rest of the Engine Compartment, so you will have to make sure that everything will Fit without Rubbing anything Important like you Distributor, Fuse Boxes, Altinator Wires, Battery, Radiater Hoses etc.

This is a lot of work and could cost you more than an aftermarket setup. This is just a suggestion and I am not trying to discourage you from making this Project.

[tjones]

Yep....custom built fun!

[krymis]

i would love to buy one and bolt it on but until kia or hyundai comes out with it i will have to make this one. As for the rubbing, it will not be a problem. I will take pics tonite of the stock setup and of the drawing concept. Here is a link for what i am thinking in terms of a design http://www.ericksracing.com/id82.html . I think that if i can design this then it will allow me to fulfill another goal. Also mustang throttle bodies are a good source to look atfor ideas. 86-up 75mm is the biggest i will go whick is not a problem. Everythng else was custom made for this engine so now instead of farming it out i will just build it. After the build i will anodize the whole body to carry out the anodized, powdercoat, and polished theme.

I forgot to ask a Question. Is this Car your Daily Driver. You wil have to remove the Throttle Body to get Dimensions to Reverse Engineer the New One that you want to make.

Also you may have to reuse some of the Springs and Hardware for this Project.

A Major Note *** Pay vary close attention to the Emissions Standards for your Area***** This is vary important because in most states (Specificaly NY, California,and NJ) have strict Emissions Laws. In NY if you change certain things you could wind up in Jail.

Here is a good Example:

My 2003 Chevy S10 Pickup has a single Exaust outlet and Dual Catylitic Converters. If I change it over to True Dual Exaust I will be reported when I take it for it's yearly Emissions Check. Then Johny Law puts me in Jail. Not only would I face State Charges but Federal Charges as well.

With this simple but costly modification my truck it would go from 275hp and 315 Foot Pounds of Torque to a 25-35 more HP and 15-25 FtTqe. BEEFY but not worth going to jail for The standard HP and Tque is only 190Hp without the Towe Package.

If in fact I had $3500 laying around I could get a Centrifical Force Super Charger that would add 40% - 60% more Juice (Horse Power and Torque) , but since I live in a Highly Congested Area, there is no point.

[sorincnc]

I am willing to help. I have a 2004 tiburon that my girls are driving. That will b cool. as far as Toby's message ic concerned:"
My 2003 Chevy S10 Pickup has a single Exaust outlet and Dual Catylitic Converters. If I change it over to True Dual Exaust I will be reported when I take it for it's yearly Emissions Check. Then Johny Law puts me in Jail. Not only would I face State Charges but Federal Charges as well.....Well that is what happens when you live in NY.....Move down to Florida, we can do anything we want here (should see my Jeep).LOLLOLLOL
Let me know if I can do anything

Originally Posted by sorincnc

I am willing to help. I have a 2004 tiburon that my girls are driving. That will b cool. as far as Toby's message ic concerned:"
My 2003 Chevy S10 Pickup has a single Exaust outlet and Dual Catylitic Converters. If I change it over to True Dual Exaust I will be reported when I take it for it's yearly Emissions Check. Then Johny Law puts me in Jail. Not only would I face State Charges but Federal Charges as well.....Well that is what happens when you live in NY.....Move down to Florida, we can do anything we want here (should see my Jeep).LOLLOLLOL
Let me know if I can do anything

I used to live in Melbourne and Had a 1987 Trans Am with and L98 350 cubic inch Corvette Engine, Complete MSD Ignition with Spark Box set a 6500 RPM Stall Speed, 4500 RPM Torque Converter Stall Speed, True Dual 3" Diameter Exaust(NO CATS) (Custom from Kooks) Holley 750 CFM 4 Barrel Avenger with a Eletric Choke, Custom Headers (also from Kooks), and 4:11 Dana Rear, 16 by 9 Dunlops Directional Z Rated P245 ZR50's, Edlebrock RPM Intake Manifold, a B&M Mega Shifter and lets not forget Speeding Tickets.

Forgot a few more things. 8 Point Roll Cage, Sub-Frames, Rear Pan Hard Rod, Lower Rear Control Arms, and a Strut Tower Brace. I was a Speed Freak, now just a CNC Freak, which I won't get Speeding Tickets of 145mph in a 55mph anymore!!!!!!!!

Someone is going to hit me in the head with a brick because I keep forgetting things A Custom made .25" Carb Spacer made by yours truely. I think that is it. Ooops!!! one more thing, that nice K&N Air Filter Ring and Lid (the whole thing was an air filter top and sides).

BTW: She ran easy high 9's in the Quarter Top Speed was around 165mph. Estimated HP at the rear wheels was 475hp. Did all the install work Myself

Given the chance to do it again I'd get and Enshu VMc with a Full 4th Axis and a Nakamura Tome Multi-Tasking Lathe with Live Tooling and a Sub-Spindle.

Below are shots of the Carb

[isaiahdakotaarm]

emissions laws? what are those?
i could walk outside with a wrench and cut my exhaust off at the end of the manifolds and nobody would say anything. I could run 2 cycle oil through the fuel system and not a person would care, of course my state has a total population of about 760,000.

that aside, Sounds like a fun project, but unless its an old vw engine, i got no clue about it. I havent done anything except change oil since i was 15 (7 years ago)

but if i can help in any way just lemme know.

[tjones]

Originally Posted by krymis

I have bobcad v21 for cad cam, mach 3 for interpretur, and a few machines i can use. I want to make an aluminum throttle body for a turbo project i am building. The setup is a 2.0L engine being stroked to a 2.3. I made a custom intake but wanted a custom 70-75mm throttle body to go with the intake. Can anybody help me get designing and machining a prototype. I will be machining it out of tooling board before using the aluminum. I want to make the butterfly and shafts and all. Where do i start. I want a 3-3.5 inch opening and the intercooler end caps and piping will be sized to what ever size the throttle body is. I have a prototype 3 inch maf made with my polymer setup.

Is Bobcad your only CAD program? If so then you need to start piece by piece. Decide what the main body dimension will be and then decide if it can be turned, milled (2D), milled (3D), etc.

Decide based on tooling as well. Do you have the drills and/or taps needed. Do you have a 4th axis? These things determine a lot of how you will do your part.

If you have a lathe you may wish to turn part of this. If not do you have key style cutting tools you can mill the slots around the diameter with?

[krymis]

i have three extra engines and this is a driver but not daily and most the stuff is not legal anyways. I will post pics of the tb tonite since i didn't get home til late last nite.