[SpeedBallDEVIL]

Good News! Prototype has been machined! It should be here late this week to early next week. This is only 1/8" and does not include the groove and is to measure up the holes ONLY. However you can see how the outer walls have been thickened up a bit to compensate for the groove. This way if you decide to throw yours on the garage concrete, it will be less likely to chip or crack.

Hopefully my measurements hold and we can jump straight into full production next week! Hopefully. I feel like there may need to be slight alterations. More pictures to come later this week!

[CaptainMorgan]

Looks pretty good at first glance.

[SpeedBallDEVIL]

Good News! I got the prototype today! Now this isn't full scale, just a mere template so I can assure everything is aligned properly. In other words its a very thing piece of sheet metal (ie. no groove).

Everything lines up very well but I will admit it is not 100% exact. However, there is very little that needs touching up and depending on your opinions I may not edit it at all. The best part is that all of the pin holes (smallest holes on the spacer) that need to line up with the ones on the LIM are all exact. So much so that I can fit the a bolt with the same diameter through all of them at once. The only ones that may even consider adjustments are the ones along the outside. However, these are off by varying slight amounts all around. In addition, these have a large diameter then the screws themselves (nearly twice the diameter). SO, I'm thinking no adjustments should be needed but if necessary, they are easy and can be done quickly.

I will let the pictures do the rest of the talking. What the pictures are is this thin sheet metal prototpye attached to the V2 intake spacer. From this, you should be able to see the differences between the two. You will find the V3 spacer to be slightly thicker (to compensate for the groove).
















One change I will be doing is extending the radius of certain fillets around the outside. Mine seem to be much smaller and I'd like the "ears" to have as much strength as possible so a little extra material won't hurt anything.

[paintballdude05]

The critical areas are pretty much dead on from what I can see, the rest are just cosmetic. If I were you, I'd do the changes to the design to get them closer to the original spacer and then just send them to production. Even if they are a bit off afterwards it's no biggie, at least they're closer than before.

[SpeedBallDEVIL]

What I can also do is get a print out of the spacer at 100% scale. However, I can only access about 60% of the spacer this way as I only have the ability to print 8x10 paper. I can't figure out how to print out half and half.

I will adjust those areas that are of slight concern and get one full scale made and install that on my car. When everything is a go. I will make 30 of them for full scale production.

[Scooter-Man]

I've reversed engineered many items in my Machinist career and that does not look bad at all. Remember, your laying a copy on top of a copy. Have you placed your prototype on top of a real LIM? Seems to be the way the plenum and LIM match up with clearance for the coil packs are very forgiving.

Looks good & you are doing a great job on this spacer plate.

[SpeedBallDEVIL]

Thats a very good point actually. I have a spare LIM from the parts car and I threw the V2 spacer on there and it was slightly difficult to install. However, after moving and wiggling it around I got it to seat properly.

When I wen't to put the prototype on there, it was a no go. I could only get the top two holes to go through the pins. The lower one (as shown in the picture below) is too low and doesn't fit properly.

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This is really strange considering I can fit all three bolts in those holes and the spacer fits fine matched up to each other. Even in the pictures you can see there is hardly any noticeable overlap. What I may just do is move that lower hole that won't line up and see if that fixes things. I'd really like to be able to print this out at home and line it up with the V2 spacer but unfortunately not :/

[SpeedBallDEVIL]

Here is how the EGR tubes will be modified. Rather then welding a single piece in line, I was talking with a friend and he suggested rather a colar to get a better weld. I could also try finding a piece of stainless with the same inner diameter but a little thicker so the weld has a better grab on the extension? Also below is the rig that will hold the tube for welding.



What do those of you with welding experience think about this?


Updated List!

If you are interested add your name to the list below:
1. Austin R/T (DI)
2. Adpros (DI)
3. YesImLDS (DI)
4. DjGreggieP (DI)
5. Bigde024 (DI)
6. Kent Vice (300M Club)
7. 300M-Mike (300M Club)
8. hrmwrm (LH)
9. chosen3001 (300M Club)
10. srt420 (LH)
11. Henry (N/A)
12. Cornelius (300M Club)
13. SilverSpecial (300M Club)
14. 02SilverSpecial6.1 (300M Club)
15. Fromans4 (LH)
16. Avalancha805 (DI)
17. akiharho- ledgic_13 (300M Club)
18. '87IROCZOWNER69 (DI)
19. BiliTheAxe (DI)
20. Mopar340dave (300M Club)
21. BXZ (300M Club)
22. BatCaveTrep (DI)
23. 99mopar (300M Club)
24. 300fam (LH)
25. 300Mazing (300M club)
26.
27.
28.
29.
30.

[SpeedBallDEVIL]

Hey guys, is there any way I can edit my first post? I'd like to updated the list.

[SpeedBallDEVIL]

Very Minor Adjustments Made! Prototype #2 getting made and shipped next week! Good progress so far guys.

Also finished off the gasket order. I have stupid money invested in these stupid pieces of rubber, PLEASE buy the gasket kits from me guys! I need to go over prices and see what I can do as far as discounts go. Should be seeing a nice 10-20% off retail!

Thanks again for following the thread and your interest! Hope to have this thing full scale within the next month guys! Full production this Spring/Early Summer! Just in time for your installs!

[crypt keeper]

PM me the list and i will change your first post.

[YesImLDS]

Sounds great. I make sure to check up on this thread every once in a while to see progress and I am very impressed!

[SpeedBallDEVIL]

Prototype number 2 arrived today. There was a slight delay because the water jet was down for a few days or so and things got backed up. Lined it up and I overcompensated for the peg hole. I increased the radius and adjusted the location for one last run tonight. Just sent the email off for the first full scale model! I should get it within the next two weeks and then I will install it and give it a test. I think I'm going to throw it in the special for now since my M has the EGR equipped. However, if i can get the first modded EGR tube done I will install it on my personal M.

We are on the final stretch!!! Who wants their spacer first :P

[SpeedBallDEVIL]

First full scale model being mailed out today. Hopefully installed this weekend! Getting very close!

Going to order screws. How do these look? Can we manage with partially threaded screws?

The current bolts I got from the V2 set are 304 stainless steel bolts with a 700 N/mm2 tensile strength. However, I can't find the 304 series on McMaster-Carr

These screws are M6 threads, hex bolt top, 90mm long, and can be fully or partially threaded. Full thread is $1.02 each. Partial thread is $0.52.

These are the same but different material and are $1.34 each and only come full threads

These are $0.37 each but only come partially threaded.

[CaptainMorgan]

You only need partially threaded for this application.