ls3/ls7 maf hole cover

[orion4096]

I replaced the seals on my AC compressor and printed out a shaft seal install tool.  Worked well except I didn't give enough tolerance and it broke when removed from the shaft.  It's awesome when you can go from needing something to having a working piece in about an hour of cad and print time.

[spacevomit]

Hey I think this might be of interest: http://m.machinedesign.com/news/think-machinist-when-creating-solid-models

[orion4096]

Neighbor's kid wants a pokemon ball printed ... never got around to that due to printing an oem power steering adapter plate today.  Hopefully the stock pump feels better than the camaro pump with turnone fitting.  I don't have the pump yet, but was able to make a template for mounting something to the head with some temporary 3" spacers.  Came out a little rough on one side due to my impatience and the print speed being set too fast.  The side the pump mounts to is pretty smooth.  I also ran out of long m10x1.5 bolts that still had their head.

[digitalsolo]

That is so cool.

[spacevomit]

That's for the regular Mazda pump? Why isn't this done more often?

[orion4096]

Yup, for the oem mazda pump.  It's easier (cheaper?) to convert lines and hook up the ls1 pump than to make a mounting bracket for the mazda pump that's square and has the right offset.  Several other people have posted about running the mazda pump and the steering feel is better.  Figured I should try the same since the ls1 pump doesn't feel right to me.  Only thing I'm not so sure about is how much under or over-driven the mazda pump is with the ls1 damper.

My friend with access to the waterjet and cnc mill just moved so I'm back to using the angle grinder for fab work.    Once the bracket is trimmed down and has mounts for the pump and the spacers are the right length I might try starting the car with a solid print just to see if it explodes.

[orion4096]

I have some 1/4" aluminum to make the main bracket out of, but what material should the spacers be made of?  They'll probably end up being 2.5"-3.5" long and aluminum seems ideal for weight and cost.  Will aluminum be strong enough to handle the twisting force from the pump, though?

[spacevomit]

Looks like most of the twisting force would be imparted into the bolts... 2024 or 7075 would be ideal as they can be made harder.

[Mik3ymomo]

Neighbor's kid wants a pokemon ball printed ... never got around to that due to printing an oem power steering adapter plate today.  Hopefully the stock pump feels better than the camaro pump with turnone fitting.  I don't have the pump yet, but was able to make a template for mounting something to the head with some temporary 3" spacers.  Came out a little rough on one side due to my impatience and the print speed being set too fast.  The side the pump mounts to is pretty smooth.  I also ran out of long m10x1.5 bolts that still had their head.

This should be a new thread. I believe you would have a lot of interest in people buying this from you if you decided to do some group buys!

[orion4096]

If it works well with the stock diameter f-body pulley I'll post up the cad files.  Haven't found a local machine shop that wants to do low volume.

Looks like the stock rx7 crank pulley diameter is around 4.625" and the f-body diameter is 7.53".  So ~63% higher PS shaft speed at the same RPM.   I PM'ed someone who makes pulleys on rx7club and he said a minimum order of 50 before they would even consider it so that's out.  Not sure a pulley that size would even fit with the idler still in there, but something larger than the stock mazda pulley would be nice.

Have all the parts now except for the tubing to make spacers.  If I can make some time this weekend, the car should be running with the mazda pump.

[orion4096]

I have to double check my measurements, but it looks like the back of the pump without the brackets needs to be spaced almost exactly 0.5" from the head.  If that's right, it makes for an easy (rear) bracket with two sandwiched 0.25" pieces of aluminum.  One with larger pump mounting holes so the bolt heads are recessed.  I still should make a front bracket, but it can be small and bolt into a single spacer.

Here's what I was thinking for the rear bracket.  The cad drawing is newer than the print to fix some clearance problems.

[Mik3ymomo]

You guys should get together on this.
http://www.norotors.com/index.php?topic=16737.30

[orion4096]

His thread motivated me to install the stock pump.  We talked about the bracket.  Not sure if either of us has the time or patience to get a bunch of these made right now, though.  I'll post up the cad files.

Finally found time to print a (quick hack) front bracket and spacer.  Came out perfect.  It's bolted in there pretty solid and I wouldn't hesitate to start the car or even drive around the block with the printed bracket.  I'm more worried about it melting against the head than cracking from the pump pushing on it.  It's still surprising that it needed to be spaced exactly 0.5" from the head.  The 5/8" return hose from autozone doesn't want to take the turn to the new reservoir without kinking.  Need a better solution - maybe braided hose.

I e-mailed KRC about a pulley and it sounds like their 6.5" fbody pulley might fit the mazda pump.  Have a friend with a KRC pump and I hope we can try his pulley this weekend.  The bracket will likely need to be redone.  Might just go with the front side bracket and 3-4 spacers if the offset is no longer something nice like 0.5".

[Troux]

For those unaware:
http://www.shapeways.com/

Submit your CAD, wait for your print in the mail. Great prices, great options.

[spacevomit]

I have some very thin titanium sheet, like shim stock, you can cut it easily. I could send you a piece. Drilling the holes might be a problem, maybe if you sandwich it between two pieces of wood. PM me the dims and a shipping address if you want it.