turbott920

So a while back I bought a used APR big port mani for my BT setup and it came with a 75mm drive by cable throttle body. After seeing the new SEM manifold and the 80mm TB it came with (nice price tag of only 175 for the TB) I decided to try to get an 80mm to fit on the APR. Unfortunatly the APR's bore was only 75mm but it had a small transition if you look on the inside where it got bigger. I decided to take the mani and TB to a friend and together we decided if we shave the outer edge of the mani back about 1/4" (after the throttle plate) the bore would be exactly 80mm. We used this really sweet machine that cuts with a brass wire and tons of little bitty archs. I must admit I was impressed. The cutting element never even touches the metal and the box in the picture below completly fills with water and all the cutting is done under water. Also the cut is smooth as glass, not one single burr. Tomorrow we will make a new throttle plate adapter to attach to the mani. Also my friend mentioned there is a "mud" type mixture you can add to the water that will completly smooth out all surfaces inside the object being cut and out (hmmm port polish anyone?)

stock TB vs. 80mm
<img src="http://c3.ac-images.myspacecdn.com/images02/8/l_a96029ab2b954e73baba9f8f74c2de76.jpg" />

checking the first cut 1/1000 of an inch) to make sure we were cutting straight
<img src="http://c2.ac-images.myspacecdn.com/images02/48/l_5371ba86bc3d4e08bce816ee51fe03d5.jpg" />

close up of 1/1000 of an inch cut of old throttle plate
<img src="http://c1.ac-images.myspacecdn.com/images02/2/l_24771472a64a4d9484038d74ff94fec0.jpg" />

notice the spool of brass wire. The machine automatically threads itself and continually feeds wire throughout the cutting process. One complete pass took 1hr 45min
<img src="http://c4.ac-images.myspacecdn.com/images02/52/l_ba3297de071d47ceb3d77a2fcdcc6a3f.jpg" />

kTTang

black rings, black valence, tinted tails :-)

stilljester

<ul><li><a href="http://en.wikipedia.org/wiki/Electrical_discharge_machining">Wire EDM</a></li></ul>

TonyStarkz

looking good! want to sell that r32 tb?

turbott920

Actually the .:R has a 75mm TB this is an 80mm. I do have a 75 DBC for sale though

TonyStarkz

Ah I mis-read...didn't see it came with DBC (hence why i thought it was an R). Nevermind.