Tdi90 tandem pump options

[audifan]

If having the spacer modified is not possible then the only other option I can see is convert the inlet to LHD. This is due to the Bosch pump being a direct fit on all LHD diesels. Assuming the air pipe and ASV do not foul the brake master then this could work.

For this you would need the LHD inlet manifold and new gasket. The LHD intercooler outlet air pipe (one piece for the BHC but 3 parts for the ATL).

The ASV and EGR are refitted to the LHD manifold but now point to the left instead of the right.

Again depends on availability of these parts..

LHD inlet manifold 045129713N
LHD intercooler outlet pipe 8Z1145708D for the BHC
LHD intercooler outlet pipes 8Z1145834A, 6E0145770F and 8Z1145838A for the ATL

 

[cheechy]

It was a carbon fibre industrial 3D printing material that we discussed and when I showed the guys what it would be holding and the fact that there is no other support for the weight of the ASV other than the mounting tube that would be 3D printed there conclusion was not a hope in hell of that working

The main draw back with 3D printing is the weakness of the bonds across the layers of plastic The plastic itself can be really strong but the layers simply split apart
At the end of the day the part would need to have a good level of confidence of working long term to go to all the trouble of making it and there was near to zero confidence of it working. In simple terms it didn’t look right. And in practice that means it will rarely work out well if it doesn’t look right

Paul


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Any ideas on cost for a ground up machined part Paul given the supply of the extensions is patchy at best (almost non existent lets face it).

 

[depronman]

To be honest I don’t really have a clue but would not be cheap just in metal alone
There are two pieces of 8mm ally plate 3” square for the end flanges then the length of ally tube about 5” long
The tube is just cut to length and face up each end square in the lathe so nothing much in that
The two flanges need profile milling to suit the pipe and the three holes adding, that will be about £30 a flange
Then I need to find someone who can weld ally as I don’t have the facilities for that, say £20 as a best guess
So you can see that we are at £80 plus ally tube and plate.
My best guess is this would end up at around £130 which is a tad expensive in my eyes

If there is any interest at that ball park price then I will look into this further.

Cheers. Paul


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[cheechy]

To be honest I don’t really have a clue but would not be cheap just in metal alone
There are two pieces of 8mm ally plate 3” square for the end flanges then the length of ally tube about 5” long
The tube is just cut to length and face up each end square in the lathe so nothing much in that
The two flanges need profile milling to suit the pipe and the three holes adding, that will be about £30 a flange
Then I need to find someone who can weld ally as I don’t have the facilities for that, say £20 as a best guess
So you can see that we are at £80 plus ally tube and plate.
My best guess is this would end up at around £130 which is a tad expensive in my eyes

If there is any interest at that ball park price then I will look into this further.

Cheers. Paul


Sent from my iPhone using Tapatalk

To be honest I don’t really have a clue but would not be cheap just in metal alone
There are two pieces of 8mm ally plate 3” square for the end flanges then the length of ally tube about 5” long
The tube is just cut to length and face up each end square in the lathe so nothing much in that
The two flanges need profile milling to suit the pipe and the three holes adding, that will be about £30 a flange
Then I need to find someone who can weld ally as I don’t have the facilities for that, say £20 as a best guess
So you can see that we are at £80 plus ally tube and plate.
My best guess is this would end up at around £130 which is a tad expensive in my eyes

If there is any interest at that ball park price then I will look into this further.

Cheers. Paul


Sent from my iPhone using Tapatalk

ok cheers Paul thanks for the background. If the extenders aren't widely available then there might be no other way I guess.
If using the spacer method is it one or two pipe extenders that is needed?

 

[depronman]

You need the origin plus one extra
They are cast alloy and can have blow holes in the alloy so I say normally one spacer will make one modified spacer but it can sometimes work out as two needed if there are blow holes in the wrong place. It’s a lottery as you don’t know where the blow holes are until you cut the spacer in half. I’ve actually only had this once but in the interest of being open and honest there is a slight risk of needing two spacers to make one modified one

Cheers. Paul


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[audifan]

Bit of lateral thinking here...
Would manufacturing it from steel be cheaper?
Would have thought that 2 identical flanges cut from the correct gauge steel by a waterjet or similar and seal grooves plus the straight pipe and 2 welds would be possible.

Waterjet Cutting Service | 9m x 4m | Charles Day Steels

Unrivalled waterjet cutting service for almost any material up to 9m x 4m. Accurate, burr-free cutting of high volume, high complexity projects.

www.daysteel.co.uk

 

[depronman]

Bit of lateral thinking here...
Would manufacturing it from steel be cheaper?
Would have thought that 2 identical flanges cut from the correct gauge steel by a waterjet or similar and seal grooves plus the straight pipe and 2 welds would be possible.

Waterjet Cutting Service | 9m x 4m | Charles Day Steels

Unrivalled waterjet cutting service for almost any material up to 9m x 4m. Accurate, burr-free cutting of high volume, high complexity projects.

www.daysteel.co.uk

if you can get orders for about 50 then water jet cutting is a viable option and as you say steel plate/tube
or I can likely get them laser cut in steel, but again there will be a minium order Qty of circa 50 off

I'm less than convinced that there is a market for so many
but happy to be proven wrong

Cheers,
Paul

 

[oko]

I may be jumping the gun as I have not had time to confirm, but I believe the easiest way to extend the manifold is by machining down a old/faulty ASV valve. I believe it will be just long enough with the flanges working out ok.
I will be looking into this, however I'm sure someone may well be quicker to check/confirm this is possible.

 

[cheechy]

I may be jumping the gun as I have not had time to confirm, but I believe the easiest way to extend the manifold is by machining down a old/faulty ASV valve. I believe it will be just long enough with the flanges working out ok.
I will be looking into this, however I'm sure someone may well be quicker to check/confirm this is possibe

Sounds very interesting keep us up to date with any progress you make on this if you could