Bugatti straight 8 cylinder with blower, design, 3D printed molds, castings , machining, assembly

[Foketry]

My drawing , oil sump

 

[Foketry]

My aluminum casting

 

[Foketry]

engine fixing brackets to be screwed to the oil sump

3D printed semi model and casting , 4 pieces are required

 

[Foketry]

Trial assembly to see if everything goes in the correct position

 

[michelko]

You are getting closer . Looks beautyfull

Michael

 

[Foketry]

I finished the 4 side covers with the Bugatti logo and the circular satin finish , as original engine
In the 2 large covers the logo is directly cast, in the 2 small ones the logo is milled with a 0.5 mm end mill

 

[Foketry]

After doing the project I printed them with a PLA 3D printer, imprinted in the red sand (Petrobond) and poured the molten aluminum

 

[Foketry]

The processing of circular satin finishing with a rubber wheel mounted on an electrospindle, 7000 rpm and a few drops of WD40 on my CNC milling machine.

 

[michelko]

Those plates came out realy nice

Michael

 

[Foketry]

Those plates came out realy nice

Michael

Thanks for your advice

 

[Foketry]

The radiator fan with its pulleys and flat belt

 

[Foketry]

To make the fan I used the new printer for liquid resin that arrived a few days ago, this printer does not leave the mark of the layers like filament printers, moreover it is much more defined and precise, the layers thickness is 0.05 mm (0,0019 inc )
This is very useful for making foundry patterns, no need to sand and paint
You can appreciate the difference in the photo of the 2 fans, one made with a filament printer, the other with a resin printer

 

[Foketry]

To put 2 bearings and an oil seal in the drive pulley without increasing the thickness I adopted this solution, the pulley is driven by the crankshaft and a transverse pin.

 

[FTX]

Hello

Great job. Very impressive.

Ftx

 

[gbritnell]

Still following along. Very nice work!

 

[Foketry]

I have improved the efficiency of the water pump, I was not completely satisfied with the previous test

the previous test

 

[Foketry]

the today test

 

[Foketry]

I replaced the old brass impeller with a new plastic one, printed with the new 3D printer and also removed the cutwater

 

[Foketry]

The pump is connected to the distribution gearbox by bevel gears

 

[OllyM]

That is beautiful work, absolutely superb! I've been using a resin 3d printer for mechanical parts (gears, brackets, mounting frames etc). One thing to bear in mind is that most of the resins are very brittle, very much like acrylic. I've used purpose made engineering resins have much better mechanical properties, although they aren't cheap. Here's one supplier that I've used:
Formfutura Engineering Resins

The clear type is less brittle, the grey type is very very strong, and heat resistant.

Cheers,

Oliver