LK9+F40 (Saab turbo LSJ) swap (Page 5/9) FieroWannaBe JUL 01, 09:28 AM quote Originally posted by KillerFrogg: Second image is the one I am going to get a quote on having it printed in AL or a high temp plastic. Shapeways list a plastic rated at 175 *C. That would be ok on an N/A setup but since i'm turbo, and this part is before the intercooler so I have to be mindful of that, but 350F seems high for a reasonably turbo setup. Sim shows basically no meaningful deflection. 0.04mm at worst. Stress visualization colors auto scale so it looks worse than it is. Highly over built but I'm ok with that. Do the math you might be surprised. Tout = [Tin + Tin x [-1+(Pout/Pin)0.263]]/efficiency KillerFrogg JUL 01, 09:51 AM Quick math says 348*F, @25psi & 70% efficiency. Yeah right on the edge to say the least. Ill have to think about that. I had figured 300-325. Realistically 25psi past where I want to be, but blowing out or melting an intake from the inside is something the engine and my wallet can live with out having happen. Finally rolled over to page two! KillerFrogg JUL 03, 11:13 AM Quick photo dump. Tore the head apart to inspect valves as recommended previously and install new valve steam seals. A lift. God. I am so happy we finally put on in the family barn. It has already paid for its self in the time saved with repairs to other cars in the family fleet. No more sketch lift arch. Still it worked well so its stashed behind the barn for later bastardization and abuse for other things. 3D printing a fit up prototype throttle body adapter. Half of gen 2, first 1/4 printed way too fast and nasty, 2nd stopped right at the end due to power flicker during a storm yesterday. Gen 3 printed much nicer, and faster actually with some setting tweaks. First 1/4 done, second 1/4 on the printer. My printer is small and not that fast so had to split it up, and the big parts take 4-6 hours, but its a set it and forget it so that's nice. KillerFrogg JUL 06, 09:24 AM Engine build up is just about done. Got a lot done yesterday. A few little things left there and there but good enough to get it on the cradle and make mounts and start fitting it in the car. Today installing clutch assembly, trans, getting the old 2.5 off the cradle and starting to get this in its place. Fitted up with Cobalt S/C intake manifold and new alternator that clears said manifold. No idea what that alternator is off of. Got it through ZZP. Kind of annoyed it does not have the one way clutch on it the original Saab alternator did and I unfortunately can not swap it over because the offset is different. Not a big deal though. Water manifold on the intake for the air-water intercooler visible. Going to pull those hose barbs out and modify them so they point toward the back of the engine to not have to worry about clearance issues with the water lines and the cabin firewall. Also visible is the oil cooler that comes on all factory turbo/SC Ecotech engines. Back of the engine mostly to show the rotated turbo with the temporary flange adapter I printed. Exhaust outlet now points to the passanger side of the car, air inlet is dirvers side, compressor outlet points straight up. Much better for piping layout. And the good stuff. The 3d printed throttle body adapter. MMMmmm looks really good. Only a little disappointed it is on the back of the engine and wont be all that visible. Will need a throttle and cruise cable bracket so its only going to get messier. This will make piping really nice and clean. Just one vaguely U shaped pipe from the back of the engine over the trans and to the TB. pmbrunelle JUL 06, 01:29 PM I hope that when you did your FEA of the 3D-printed intake piece, you used the degraded material properties (less stiff, less strong) of the plastic at high temperature... a reminder if you didn't. It is not like the properties are flat from room temp to 175 °F, then they drop off a cliff. Also, you're using deflection in the middle as a design criteria, rather than stress? That double-hump thing looks like it could be replicated with metal (steel or aluminium) tubing, welded onto the inlet and outlet flanges. I'd also run some more analyses to see if the small mounting ears up top are stiff enough; looks like they would flex, and that the gasket in the middle would not be adequately compressed. KillerFrogg JUL 06, 01:54 PM Those studies were done in a generalized aluminum more as a "am i grosly underestimating anything".I plan on having it printed in aluminum, and i need to nix the tabs to fit the build volume anyway. The original supercharger mounts in the same way, and the base flange is 10mm thick. And yes it could be fabricated, but its a 8+ hour job between the two flanges and the welding. The shapeways Al prints come out comparable to castings and would only need holes drilled to size and tapped, then a bit of time with a belt sander to clean up the two flange surfaces. Their high temp plastics were appealing because of a larger build volume but the temp safety margin is a bit tight for me. KillerFrogg JUL 07, 09:31 AM Got the quote for getting the intake printed adapter printed. That is going to be a hard NOPE. $3500. Eh oh well. Fabbed it is! Will JUL 07, 09:36 AM I was wondering where you were going to get metal printed cheaply enough for a Fiero project... 86FieroCentPa MAR 02, 06:19 PM Just thought I'd take a moment to bump this and see if there's been any updates. Looks like we're both doing very similar swaps; LK9/LSJ and F40 with Haltech standalone ECM. Here KillerFrogg MAR 02, 10:46 PM Still here and still working on it! Since I had last posted I haven't made a ton of progress but its till going slow and steady. Not long after I made my last post I hurt my self working on the car, a grinder got away from me and got my leg on the way into orbit and I ended up with 8 stitches and 13 staples. Had to put things on hold for a bit while that healed up and I got a bandsaw instead. Got about a week to work on the car then schedule at work got crazy and I have been working 6 days a week + overtime some days almost every week since. Since then I have the engine/trans mounted to the cradle, using custom mounts. I don't recall if I had posted but I have the axles and about 75% of the fuel system in hand, just need the regulator and lines/fittings. Axles are factory SS/SC cobalt axles. The inside spline fits the F40 and the outside fits the Fiero spline and they are so close to the correct length that it doesn't mater. Using an AEM E-85 rated pump + 60lb injectors. Fuel pump hanger had to be modified a bit for the new pump but i think it can be made to work as is. Made some changes to the factory fuel rail as well just to clean up the hose routing as well as remove the restriction from the stock regulator. Building on the last few posts here, I am getting the throttle body adapter CnC'd in the next week or so. More on that later. For now progress will be slow till winter is over and my family unpacks the barn and I can get back the space I need to start working on things again.