[Dzuari]

(Sorry if this might be the wrong place, i don't post to often here but i figured IC is the most relevant category.)
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For those of you who might not know, I work for Phillips Patterns & Castings in Muncie, IN, an aluminum Foundry and Production CNC shop. We making American made parts and I am an engineer, Foundry worker, Machinist, pattern maker, business manager.

This is my build of a 671 supercharger, for my company, i started with a machined model, designed the pattern and coreboxes from it. Once the pattern and coreboxes are done i will be ready to makes some castings then machine them in our CNC shop. Once we have a completely machined case i will be making a video of the entire process.

For anyone who is in manufacturing, interested in how things are made or just wants to show support for an American manufacturing company, you can follow us on facebook at www.facebook.com/DiamondP We post all of our builds and will be taking you through the in-depth processes that are required to manufacture a product.

If anyone has questions, feel free to ask.

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Day 6-

Machining pockets into the 1" aluminum plate that will be the pattern board, the blower pattern will be located and mounted on this board.


Done



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Machining the pockets



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1" aluminum plate setting up for machining



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1 of 2 coreboxes, rough cut



Day 3-

Finished, The Lines you see are just pencil marks, now just need to mount it to a board, flip it and machine the underside pockets and cope coreprints




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3rd layer finishing cut





Third layer cut and glued, rough cutting it then finish cut with a 0.25 ball mill, should be done today then start cutting the core boxes next week.





Second layer completely done, will cut and finish the top tomorrow.





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Finishing cut on the second layer, tolerance ±0.0005, Z level drop is 0.0020. Half way done



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a photo of the CNC machine cutting the pattern, im cutting this in 3" layers of renwood. The layers are just super glued together then i post-process the tool paths and drip-feed it to the machine. This photo is of it doing a Z plan cut and leaving a 0.0500" machine stock.



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This photo is the designed pattern i am cutting.



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This photo is what the finished casting will look like.

[stevehuckss396]

It will be cool to see how it's really done. I'm watching!

[dynosor]

Thanks for sharing!

[Dzuari]

Day 9:

Pattern is done, ready to start cutting and mounting the gating and risers to it, second corebox has started to be machined and should be done by tomorrow. Still waiting the hear if we are buying a new flask or not to mold this. Also took a quick video walk around of the shop.

[ame=http://www.youtube.com/watch?v=9Ai_hkUV9Dg]671 Supercharger Pattern Walkaround - YouTube[/ame]

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machining the pockets out of the blower




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Machining Pockets




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Pockets done




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Day 8-

Mounted the blower to the plate, machining the rest of the pockets and the pattern will be done.

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Screws



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Screwing down the blower to the plate



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Picture of a camera taking a video of what im taking pictures of



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Painting and sand the corebox and blower




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Day 7-

Plate done



Finishing Cut on the second layer



Rough cut of the second layer done




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Rough cutting the second layer of the first corebox



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Cutting the cope coreprints

[Dzuari]

Day 12:

Second corebox is done, cutting the loose piece then the tooling will be ready to take over to our foundry, but i found out over the weekend it will be 1-2 weeks before we get our flask in to start molding . ill still make the gating and risers though.

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Unloading the pattern



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Rough cut of the first layer, second corebox



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Finishing cut on the first layer



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Second Corebox Done



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Starting on the loose pieces

[Dzuari]

Day 13:

Got a lot done today, finished the loose pieces for the corebox, fitted and painted them, started the basic layout of the gating and riser system of the pattern, took the coreboxes over to the foundry and made a few to get the weight of sand we will be using to calculate how much it will cost. Will be cutting and fitting the gating and riser system for the next few days.

also i added a photo of the intake to supercharger adapter plate we will be making.

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a photo of a few patterns we've cast in the past , some of these patterns are 50+ years old, some even hand made.



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3D printed pattern of our supercharger to intake adapter we will be casting, going to be making the gating system on it for the next few days.



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Loose piece rough cut



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loose piece finishing cut



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Loose piece sitting onto of the corebox



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Loose piece in the corebox



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Air set station



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Sand hopper



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Sand striked off and setting in the corebox



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Core dumbed out and loose piece attached



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Cores, will be glued together before they are placed in the mold.



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Hard to tell, didn't get the camera straight, but this wall has negative draft of 3° from the corebox parting line, thats why we needed loose pieces



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Risers roughly marked out for placement, will be cutting and mounting them soon



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Gating system of the pattern, drag side, will be the same on the other side, 2 man pour.

[slowlearner]

Dont you use filters under your sprues?

[Dzuari]

Dont you use filters under your sprues?

yes we have a couple different kind, just depends on what the customer wants, ceramic, steel, fiberglass, weaved, foam, coated, uncoated.

[mcphill]

Love the post, keep it up!

[Dzuari]

Day 14:

Tuff filling the seam lines of the pattern




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precision drawn riser blueprint



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to scale riser layout



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Riser pads cut and drafted 7°





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Grinding the risers



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risers line up



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Risers layed out on the pattern, these will be squeezed in the mold then lifted from the top before the pattern is taken out of the mold.



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The pads will be mounted onto the pattern with positive draft, the risers are drafted to pull from the top of the mold.

[stevehuckss396]

This is cool as hell. Can't wait to see it cast in aluminum.

[FPV_GTp]

HI , great to see such fine work and good old American Muscle Car industry manufacturing still alive and kicking ........... not via a boat from China

Keep up the great workmanship.

Cheers

PS- Been on your " Diamond P Industries" website - do you ship parts to Australia ?

[Dzuari]

HI , great to see such fine work and good old American Muscle Car industry manufacturing still alive and kicking ........... not via a boat from China

Keep up the great workmanship.

Cheers

PS- Been on your " Diamond P Industries" website - do you ship parts to Australia ?

yes we do, most are around $55 flat rate boxes but some can be more, just depends on the product and how many you buy.

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Day 15:

Spot gluing the pads to the risers so they will all be drilled equally, you can also see the center lines and drill lines marked with a thumb gauge and razor.




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Drilling 1/4" holes through the pads and risers, all 1/2" from the outsides so that ever riser will fit every other pad when molded.



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you can see the center-line and drill line marked on the pads with a thumb gauge and razor.



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all done, now just break the pads off the risers



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Cut and ground 1/4"-2" dow pins to locate the pads to the plate and for the risers to fit.



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The risers are re drilled with a 5/16" drill allowing a 0.0625(1/8") tolerance of the diameter, or 0.03125(1/16") radius tolerance from the pins, allowing each riser to be interchangeable to any pad.



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Pads glued down and ready to drill the plate to fix the pins.(just stuck them in the pads to take the picture for now)



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You can see that the riser is allowed to rock a little bit from the tolerance drilled out earlier.

[slowlearner]

Are you making the wooden fillet shapers that I have seen in a couple of your pics? I like the disposable concept and if somebody is selling them I sure would like their name. The time you have spent showing the forum our trade is commendable. I always wanted to build tooling for small block Ford castings, back when castings were more affordable. Just never found the time.

[Dzuari]

Are you making the wooden fillet shapers that I have seen in a couple of your pics? I like the disposable concept and if somebody is selling them I sure would like their name. The time you have spent showing the forum our trade is commendable. I always wanted to build tooling for small block Ford castings, back when castings were more affordable. Just never found the time.

not sure what you're referring to, if its the wooden sticks, those are just pop sickle sticks that i cut and grind

[kNucklBustr]

that blows.

sorry had to do it. Worked on B and R model Mack gravel and cement trucks, back in the day. Some had 671s and the early cements had 471s running chain driven barrels. I was a diesel mechanic for a co. who built the PA turnpike. Overhauled many 671/471 motors and blowers.

The interesting part will be when you get to machine the rotors. That Id like to see, 'How Its Made".

[Dzuari]

that blows.

sorry had to do it. Worked on B and R model Mack gravel and cement trucks, back in the day. Some had 671s and the early cements had 471s running chain driven barrels. I was a diesel mechanic for a co. who built the PA turnpike. Overhauled many 671/471 motors and blowers.

The interesting part will be when you get to machine the rotors. That Id like to see, 'How Its Made".

ya that's going to be fun, as of now, we don't even know if we will be able to turn a profit for them, but then again we don't just do this for money

[RICHARD ZASTROW]

Dzuari, FYI there are a couple of Pfauter rotor hobbing machines available on the used machinery market.LOL

Dick Z

[FPV_GTp]

Hi, was also thinking about the rotors and how are your going to make them ? or out source them?

Also are you making any manifolds to suit popular V8's ( chevy , ford , Dodge etc...... ) ?

Cheers

[Dzuari]

Hi, was also thinking about the rotors and how are your going to make them ? or out source them?

Also are you making any manifolds to suit popular V8's ( chevy , ford , Dodge etc...... ) ?

Cheers

As of now, we plan on castings the rotors and 3D machine them ourselves.

we are not making any manifolds as of now, going to get some superchargers out, intake adapter plates, then move on to full manifolds. however, I was told a few days ago that an engine builder here in town that builds most of the race engines for everyone around here wants to speak with me on making some intakes so it might be sooner than we plan, they mostly specialize in turbo diesel truck pullers, but did build our 489 alcohol bbc and rebuild our 427 L88. If i was to guess on our first one though, it would probably be gen 1 sbc intake.

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day 18:

Was told today that the flask should be in tomorrow, depending on if it comes in early in the day or late, ill have castings by tomorrow or wed.

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Here is the CNC we will be machined and boring the cases on, 92' mazak 6 pallet 4th axis


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Counter sinking screw holes



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hand tapping screw holes



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a precision blended Crisco and aluminum shaving tap and die lubricant



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drilling out the holes for the riser dow pins



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pins are all pressed in, we actually put them on a lathe and filed them down a few thousands because they where pressing in a bit hard



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Start of the gating system, ground down to the 3° on the core print



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Sides are drafted from 1.5° from bottom, bottom width is 2"



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Blocks lined up



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Blocks cut and ground to fit





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top view of the draft



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ground down to allow the metal to flow smoothly



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runner bar and basin cut and shaped with 5° draft




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drilled out and screwed down