Popular Post Not-a-number Posted September 4, 2016 Popular Post Share Posted September 4, 2016 Discussion Thread - //oldschool.co.nz/index.php?/topic/53921-bugatti-t5759-engine/ Embarking on an ambitious project to build a Bugatti T59 Replica. Using modern manufacturing techniques, 3D scanning, 3D printing, CNC machining but keeping all visual details authentic to the original. 83 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Decided to start with making the cylinder block first. These are photos from a guy in Germany with a genuine engine and also an old sectioned one. He needs a new block himself so he is doing everything he can to help. The Bugatti way of doing things was a bit different when it comes to the engine. The block is also the cylinder head so there is no headgasket! 13 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Fitting 3D printed patterns to get the CAD right. 21 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Crankcase. Then once I knew the CAD was right it was time to make the negative CAD for cores and pattern making. Then take those parts and make patterns. Making just 1 of the 8 cylinders first. Just to get the casting right. 10 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 First sand core. Cylinder and port core. 16 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Then time for the outer patterns. Filter and sprue area added. Then fit them all together. Then stack them on top of each other to make a 40kg sand castle. 17 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Ready for the first pore. The guy at the foundry likes classic cars and was really keen to help. Will charge $5 a kg for casting. Thats cheap! The filter area was too thin and failed after it filled up. So it filled properly and then just before it solidified it half drained out. . I knew it was dodgy but thought I might get away with it. Even though this failed, this is a great success. The cores worked perfectly, they didn’t shift or break, the surface finish is great and there are no cracks or porosity which is really common around the port and cylinder head areas. This is definitely the coolest thing I have ever made! Next step is to cast two cylinders. 15 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Did a bit of machining and chopped it in half. Added some valves to make a proper paperweight. Finished off the moulds for an attempt on 2 cylinders. At the foundry now and theyre meant to pour it early next week. Fingers crossed it works 15 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Great success! I have a twin cylinder block and I'm pretty stoked! Been working on this thing flatout. Along with everything else though so not as much done as I had hoped! Made a full 8 cylinder pattern. Got this machined at Jacksons electrical who do a heap of patterns for us at work. Turns out Rookies mate works there so he did a real sweet deal. Did a good job too. Guys at work Duratech coated it. Awesome stuff to sand down, smooths everything out. 15 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 The first mould didn’t work out! Mixing the sand in small batches didn’t work out. I couldn’t mix the sand fast enough to get an even mix so ended up with layers that didn’t go hard. 70kg of sand for the garden. Employed an apprentice/the mrs to run the mixer and had another go. Second attempt worked pretty well. Sand started going off too quickly again so there are a few dodgy patches. Can seal up the dodgy bits with resin. This didnt really work that well. Adding that red resin was a bad idea apparently. It would gass off and cause problems. So went to the foundry and filled the patterns there. Time to fill it up with water and cylinder cores now. Theres 165kg of sand all up! Not easy to work with! 15 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Dropped the second half on with no drama. So its all bolted up now and ready to go to the foundry at the end of the week. Nailed it Thats like 1000hrs work right there! 47 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Been talking a bit with the guy that owns the Hamilton car museum. He bought the T57 from the Baillon collection in France. His engine is essentially the same as what im building. Hes given me access to any parts I want when hes got it in bits. To copy and 3D scan etc.So Ive got some pretty cool parts sitting around the living room now. The sump is a beastFirst ali bit cast! Right hand cam gear cover. Using a David 3D light scanner. Sort of useful to help with drawing in CAD More 3D printed moulds. Perfect for part this big with this detail. Would of taken me days to machine it. Still have to do a lot of sanding and paint to get a good finish. Playing with different filter runner designs. Think im getting a better idea of how to do it. 2016 on the left and 1938 on the right! 70hours from start to finish. But only bout 3 hours to make another one. So I plan to make atleast 3 of each part. 27 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 5, 2016 Author Popular Post Share Posted September 5, 2016 Cheers for the comments. Hours and hours of work there! A lot more to go! Yesterdays work. Two more cam gear covers, off to the foundry tomorrow. 22 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted September 6, 2016 Author Popular Post Share Posted September 6, 2016 Dropped the moulds off in the morning and had the parts by lunch time! Thats service. The first one had a bit of shrinkage going on in the thicker parts so they dropped the temp a bit on this pore and it worked mint! This is only the right hand side. Left hand side is pretty much the same just doesnt have the cutout. 31 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted November 17, 2016 Author Popular Post Share Posted November 17, 2016 Bit of CAD on a T57 front spring hanger. 33 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted December 11, 2016 Author Popular Post Share Posted December 11, 2016 Making patterns for the spring hanger. Got a 3D printer! Does work for you while youre at work! So good. 27 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted December 20, 2016 Author Popular Post Share Posted December 20, 2016 All the outer moulds made with runner/sprue etc. Time to work on the inner core patterns and hopefully pour one early new year. Working out runner system Lower half of the mould Upper half with sprue and filter 33 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted December 31, 2016 Author Popular Post Share Posted December 31, 2016 (edited) Bit of CAD. Slowly slowly getting there. Most major parts are detailed. A lot to go. Edited January 3, 2017 by Not-a-number Fixed images with imgur 16 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted January 3, 2017 Author Popular Post Share Posted January 3, 2017 Real crank in the lounge. 55kg beast! 27 Quote Link to comment Share on other sites More sharing options...
Popular Post Not-a-number Posted January 3, 2017 Author Popular Post Share Posted January 3, 2017 All the patterns and moulds finished for the Spring hanger body. Ready to go to the foundry. The sand isnt great (I think the resin is going off) but its worth pouring it anyway to see how it works. 25 Quote Link to comment Share on other sites More sharing options...
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