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Old 08-12-2011, 12:21 AM   #1
godzillus
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Default 1969 simca 1118- Homemade Cast Aluminum F.I.

Hey Guys!
Posting up my Simca Project after seeing that FLAWLESS 1971 Bavaria on the blog. I told myself that I wouldn't post anything until I have more stuff done, but I can't resist! I recently Finished My ITB/Megasquirt Setup on my first car, a 1957 Chevy wagon and moved on to this sweet little french car I picked up for 300$ in town two years ago. The engine was seized( finding parts is sort of like living an Indiana Jones Movie) and is in desperate need for proper stancing. I am in college, so progress might be slow but I am super motivated to learn alot on this car and have an idea for the end product. I will be building a turbo ITB setup with sequential injection (MS3) and casting my own parts, ie, TB's Valve cover, fuel/vac blocks etc.




































MS3 kit. Dual Core(!) Processor



Wooden male form for aluminum casting.



Mocked Up on the ground. will not be this low but I just wanted to check it out. I ordered some 15" drag dr20's coming in soon.

Last edited by godzillus; 10-06-2011 at 07:26 AM.
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Old 08-12-2011, 12:53 AM   #2
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sub'd for more!
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Old 08-12-2011, 01:05 AM   #3
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I have to say your Chevy wagon is effin sweet!!! I have never understood the ms systems but props to ya on what you have done
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Old 08-12-2011, 01:08 AM   #4
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I like your style sir. I saw that Bavaria you speak of in person and I really liked it as well. Your old chevy and the bug in the pic are quite nice and I like where your new project is headed... to the ground!

Keep up the good work, I'll be peeping this thread as it progresses for sure
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Old 08-12-2011, 01:25 AM   #5
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this might be sort of a newb question, but how do you have the ability/ideas/materials to cast your own parts?
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Old 08-12-2011, 01:42 AM   #6
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I have a foundry(made it), a lot of wood working tools(Dad and great uncle were wood workers) for forms, and my dad's best friend owns a glass blowing studio and has all sorts of refractory material and knowledge. You have to build the form 5/32"s per foot bigger in scale than the final part to account for shrinkage during solidification. But really, anyone can do it, doesn't have to be wood though. It just has to stand up to ramming sand on it. Check out the DIY on vwvortex on casting. I will post some pics of the process soon!
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Old 08-12-2011, 01:57 AM   #7
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that's awesome. good stuff, keep it up! Will be following this for sure
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Old 08-12-2011, 02:11 AM   #8
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good stuff ahead

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Old 08-12-2011, 02:45 AM   #9
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It should be that low, or lower. Awesome project ahead of you, keep us posted.
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Old 08-12-2011, 03:30 AM   #10
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grrr I knowww! Im trying to be a responsible adult, But I agree. I'm picking up the wheels tomorrow so we will see. I got the 40+ mm offset so flares of some kind might be in order.(I don't know, I'm winging it, never seen another one in real life, let alone slammed). these have a hillclimb/rally heritage in Europe, so I would like to pay tribute to that a bit. Also, these things have a goofy transverse leaf as the lower control arms, so it will take some effort to get it to work right.
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Old 08-12-2011, 05:45 PM   #11
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Wheels got in! I need to figure out the lug/studs on this thing, since the stock bolts wont work. I need to make lower a arms for the front, as the transverse leaf just wont go low enough! I flipped the ball joint to the top side of the spring and made an aluminum spacer, but no dice.

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Old 08-12-2011, 07:51 PM   #12
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Flip the leaf!

Also, I LOVE the ITBs on the small block. I bet it sounds amazing,
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Old 08-12-2011, 08:26 PM   #13
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yeah it does!

http://s259.photobucket.com/albums/h...t=SAM_0263.mp4

Flipping the leaf would require the subframe and footwell to be notched, as well as make the upper a arm at a nearly vertical angle. I would like to build a legit suspension, so Im thinking of relocating the uppers 4" up on the frame and building adjustable lower control arms, then find some motorcycle coilovers and mount them in the stock shock position.
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Old 08-12-2011, 08:35 PM   #14
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That definitely sounds like the way to go, especially with your fabrication abilities. It looks like the new UCA will have to be quite a shorter. If made adjustable it could serve as your camber adjustment.

This looks like a really fun project!
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Old 08-12-2011, 09:00 PM   #15
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ill watch, i want to see where this goes.
good progress so far.
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Old 08-12-2011, 11:18 PM   #16
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yeah the upper will have to be remade as well it seems. I have a stock pile of rod ends and there is an offroad shop in town that might sell a 5/8 fine thread tap for making tube ends. I'll call around tomorrow and see. In the meantime, I'm bondoing my molds for the t.b.'s and mixing up my greensand to make some initial casts. Wrestling with photobucket now. oh well, back to work!
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Old 08-13-2011, 06:03 AM   #17
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You just have to build this





I'm also going to use this for my 16V simca (On RR forum ).

Then you can you use a coil over set instead of the leafsprings !
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Old 08-13-2011, 07:58 AM   #18
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That Chevy looks so cool. Link for more pics of it?

The Simca is promising also, when it's done, it should be quite an eye-catcher. Good luck!
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Old 08-13-2011, 01:17 PM   #19
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Details on your ITB setup for the smallblock!
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Old 08-13-2011, 01:52 PM   #20
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Old 08-26-2011, 10:45 PM   #21
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Here are some pics of my first pour. made some ingots out of old pistons and the old runners of the weber manifold I used for the chevy. It may not look like much progress, but hey!




Do this with real boots and a long-sleeve shirt




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Old 09-06-2011, 10:48 PM   #22
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Quote:
Originally Posted by Rainer View Post
That Chevy looks so cool. Link for more pics of it?

The Simca is promising also, when it's done, it should be quite an eye-catcher. Good luck!
http://www.jalopyjournal.com/forum/s...fuel+injection

forgive my style of thread writing(or lack thereof) im kinda all over the place. lol

Quote:
Originally Posted by 65Mustang View Post
You just have to build this





I'm also going to use this for my 16V simca (On RR forum ).

Then you can you use a coil over set instead of the leafsprings !
oh cool man! yeah I want to build that! got some thickwall tubing. REAL tubing(my friends always make fun of me because I usually use blackpipe from the harware store haha. not this time! made a new subframe for the a arms and steering to mount to:



so for the simca, I want a totally modern control system, but use old-school hardware and techniques. I plan to build an ITB setup, cast my own throttle bodies, intake, valve cover, and timing chain cover. I also have a small turbo from a subaru that I want to build a fully equal length, gas welded header for. I plan on having the tb's draw directly from a deck mounted intercooler. these rear engine simca have fairly big louvered sections that will duct strait into the intercooler. as i am mounting the rad in the front. I will use the other set of louvers for intake air.
decklid:

Here are some Pictures!





the start of the manifold. everything upsized by 5/32 per foot



Fuel Injector register with registers for bolts to clamp a cap to the injector. I will run hard lines to the caps from a fuel block like an old f1 lucas mechanical system. Real Injection systems don't have those cheesy extruded ally fuel rails! haha



registers glued on.


Carriges glued on for the core mould to ride in. I got some sodium silicate that I will use to make co2 cured cores(so they are very strong but can be broken down with water after casting). this manifold will not be to radical, size wise, since I plan to make 100-150 hp. I will go from the standard port size to a 1.5" throttle plate.



Split in half for aranging in the cope and drag. I still need to get rid of a few undercuts but I hope to cast it after a little more practice.

I got some petrobond sand and did a cast of a head I made from clay to see what the detail was like.





the mould had tons of undercuts, but its promising!



Then I made a two piece mould for the throttle bodies.







And cast. I will show more pics of the cope and drag, gating, venting etc. if anyone wants.



I still need to work on my sprue work as there was some odd shrinkage that could have been avoided with a bit more hydrostatic pressure.



I machined some surfaces just to see how well it does. Really soft! I wonder if casting alloy (im guessing im using 356) ages? it sort of feels like lead, the way it cuts
Anyway, small victories! And I'm marginally smarter than a bronze age foundryman! more soon I hope!



I worked more on the throttle bodies this weekend and think I have the technique down a bit better. this time I made a sand core for the center as I don't want to spend hours on the lathe hogging them out(and its good practice for the tapered sand cores for the manifold)
first i made a core mould out of 2" sugar pine:



then I split it and put in a locator dowel:



then I painted it to seal the grain. next I mixed a small amount of sodium silicate and sifted play sand and rammed it into the mould. I don't know the mechanism, but sodium silicate sets up hard when introduced to c02, so i unplugged my regulator from my welding tank and pushed it into the small hole in the back of the core mould:









packed down. this is the oil based moulding sand. Its expensive but tons better than my mix of water based sand in terms of workability and detail. I don't know how the old-school guys do it!?!

I cut the gates and breathers into all the high points, set the cores in and cast it.



you can kinda see the core in there.





here you can see the core carriages that I added on that locates the core concentrically.



after some machining. the bore is still roughed out and the throttle shaft and bearing journals need to be cut. I will also cut an o-ring groove in the back. I also finished the manifold mould and cores and even cast one, but because of lack of sleep I put the flasks on backwards!!! looks like a salvador dali piece. good thing sand can be reused and the aluminum can be remelted. I didn't really like my core mould for it anyway so Ill try to build that better. More soon.

please if anyone has questions or comments just post up! I really want to start a dialog on casting aluminum as it seems its a lost art, at least in terms of a backyard hobby. everyone builds welded aluminum manifolds, or machines stuff out of billet, but there is something to be said for a nice cast piece. at least its cheaper than buying a cnc or TIG! lol
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Old 09-06-2011, 10:52 PM   #23
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That thing is sweet, I also love the beetle and chevy haha
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Old 09-06-2011, 11:21 PM   #24
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Quote:
Originally Posted by jacbo View Post
That definitely sounds like the way to go, especially with your fabrication abilities. It looks like the new UCA will have to be quite a shorter. If made adjustable it could serve as your camber adjustment.

This looks like a really fun project!
yeah the upper will have to be about 3"long!! I was thinking about a mcpherson arrangement as well.
I also found out this thing has 98mm wheel bolt pattern and my wheels are 100mm. wut..

also, nearly all of the external engine bolts are m7's which aren't to be found at any of my bolt suppliers.
the french always just HAVE to be different. lol

i want to run 165/50/15's but they are on back order from where I buy and I would rather spend money elsewhere at the moment.

it may end up if i find a parts miata for a good price (<300 bones) I will ravish all of its spindles, suspension and brakes, that way I'd have disks all around and the right bolt pattern, but it would be also neat to see if I could soup up the oem stuff because I've heard the stock drums are not terrible on these.
I need to do MATlab homework now, gahhhh............................................ ................after I order some supplies and parts!
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Old 09-06-2011, 11:27 PM   #25
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I'm thinking air suspension too....

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