Automotive Intake Manifold – Boss 302 Independent Runner

Been a while but I made patterns for the air filter for this induction system. I've been learning CamBam, Gcode, getting acquainted with my CNC Router, and made this the pilot project for my first CNC’d lost foam patterns.



Best,
Kelly

 

Yes, manual. I had to break the Machine Ops into separate programs where a tool change was required. The top side of the lid required four tools. The other three sides 1-3. There were at least 3 different ways to make the chamfer. I just used a profile cut and specified the bit diameter as .001" so it cut on the center of the V-bit at my selected depth but there were several plugins available to do same and break edges.

Yes, had that thought through while designing the parts. Besides feeding he part, it also needs to help keep the parts flat during molding.

Best,
Kelly

 

Yes, that is on the near term list. I kind of like the wax applique I have but there is a clear polycarbonate lid I intend to cut and it will need to be engraved.

I was reading on importing bitmaps for the more unique/custom artwork but I see I can download just about anything I want as far as logos. In general, what type of file is best/easiest to import that will allow you to insert and get right to it? Will probably use somewhere between a 1/16"-1/8" ball nose to do the deed.

Best,
Kelly

 

Been a while since I updated the post. I know you guys like pictures so here they come. Gated the filter patterns…..



Dip coated…..



Dried overnight….



Molded...



Casting came out nice.....I like it when they look just like the pattern!



Too tired to de-gate it today. -More to come.

Best,
Kelly

 

More pictures! I cut the air filter casting apart separating the base from the lid.



Then trimmed the remainder of the feed system off the base.



I’ve learned not to get too aggressive on the table saw and leave myself ample room. I clamped both to the mill table and shaved the feed and support features down, then hit them with the small disc sander.



They stayed remarkably flat….very pleased with that, but they could easily be straightened if needed as the castings are in a fairly soft state of temper. The shrink was right on and the interface features align very well.



A one and done….thankfully.

Best,
Kelly

 

Thanks fellas. Did the finish machining and made the mounting hardware today. Just need to splice together a filter element and it’s done.



Best,
Kelly