| STAGE 1. DESIGN AND MODELING | |||
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Regardless of the engine type, exhaust and engine builders are presented with a very challenging spatial problem when designing a tubular exhaust header system. Multiple complex branches made of arbitrary straight and bent sections of preset ODs and lengths have to be arranged in the best possible way to create a compact package that is also easy to fabricate. But determining which one is the best layout among all the possible pathway combinations the runners can follow is the real challenge . If we define the solution to this problem as devising a method to explore as many combinations as possible and zeroing in on the most feasible, at minimal cost and in the shortest period of time, a strategy to tackle it can then be drawn. |
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By breaking up the overall solution to this problem into a finite number of partial solutions that can be solved one by one, the design problem is dramatically simplified. icengineworksTM , earning various patents in the process, has successfully turned these partial solutions in our problem into modular, interconnecting straight and curved plastic modeling elements or blocks of certain OD and same length that faithfully represent round metal sections in an exhaust header design. This is Stage 1 of icengineworksTM precision exhaust header modeling systems. | ||
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The system requires the user to have already the exhaust header flanges (not included) with stubs installed in the engine. Also, the collectors must be supported in their tentative location. When assembled, these blocks form strings that serve as 3D models of actual primary runners. By carefully choosing and positioning each block added to an assembly while keeping track of the length, the designer quickly discovers the most optimum pathway between the header flange and the collector. If interferences are found along the way, the blocks simply get rearranged . This new design capacity to do and undo freely, opens up an unprecedented opportunity to quickly create more efficient, tighter and seemingly more complex designs. And the savings due to unnecessary labor and wasted materials start piling up right away. |
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It is now possible to design, revise, correct and rearrange, almost endlessly, at no extra cost, without waste, any design of yours until every aspect fits and feels right. Specific design intent can easily be introduced such as minimize number of sections per runner, plan for location of welds, or steps, design with CNC bending for production in mind, etc. When you are ready to fabricate in metal, you will find that all the information required to build the design is already at your finger tips. Stage 2 of the icengineworksTM system simplifies the building and fabricating of an exact metal version just as easily, quickly and confidently. |
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STAGE 2. FABRICATION AND WELDING |
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J- or U-bends are all it takes to turn designs modeled with plastic blocks into a full metal version thanks to the fabricating tools icengineworksTM has developed to complement the system (for more info see the header fabrication tools page). Partial angle bends are no longer necessary, which drastically reduces your required metal inventory. By utilizing precision U-, or J-bends of matching CLR, available from exhaust components suppliers, it is very easy to transfer your design model into metal, section by section. Using a vertical band saw (10" or more of throat capacity) for metal cutting, the icengineworksTM aluminum Pivoting Table attachment (p/n PIV1000) and the HDPE plastic Tube-Cutting Spacers (Series or tubing OD specific) simplify the task of accurately cutting the bent sections. Then, the innovative tack-welding clamps become extra sets of precise hands that don't get burned or tired, and while keeping a firm hold of the tubular sections to be welded. |
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| The fabrication process starts by recording your design information, section by section, on the provided Metal Control Sheets. These become the blueprints and shopping list for your specific design. They are also the way to do repeats later on of the same design. Then, each section according to the list is cut by creating and placing an equivalent section made of blocks, on the PIV1000 and around a CLR-matching Cutting Spacer. The spacer is spun until the end of the plastic section gets aligned with the band saw blade. Then, the spacer is tighten to fix its location and the plastic section is replaced with the actual metal U-bend. |
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| By adjusting the band saw's rip fence so that the blade aims at the center of the pivot on the aluminum table, the U-bend gets cut by gently pushing the Pivoting Table attachment into the cutting blade. |
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This process yields all the parts required according the Control Sheet recipe, to assemble each of the modeled sections, with each section labeled with information such as the cylinder they correspond to, the section number in that runner, and its orientation, for example indicating which ends point downstream and their witness lines. | ||
| One at a time, and for each runner, replace each model block sections with their metal version by aligning their witness lines and tack-weld. Continue until the entire design is completed. |
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Click on the features link to review in more detail the design possibilities the icengineworksTM exhaust header modeling block systems have to offer. |
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