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Sorry to hijack the OP thread one more time, but as is is regrouping a lot of cool struff about the 906's...
So, last time, I showed the patterns for the front uprights, which are comon to 904 and 906. Here is a major step forward :D
Attachment 365742
Only a few gazilion parts to be done!
Here is another "big" part (not done by me, but a close friend, with the same addiction):
Attachment 365743
If i'm a bit lucky, I may show you an oil cooler in the coming months, as well as some other gearboxes parts!
Olivier.
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Very cool part Olivier! Here are a few more photos of that Magnesium 906 gearbox casting.
Attachment 365763
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This one was listed at $21,000 on eBay back in Sep 2013...
Attachment 365765
...and no clue on what the current market price-range for once of these completed could be.
Attachment 365766
Received these beauties from Germany this week. :rolleyes:
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Not the same casting Armando. A completly new mold. And this one actually shifts.
If you want one, the price is much more reasonable. Not cheap but more realistic...
Olivier
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Has a stress analysis been performed on the front uprights? The Porsche ones were a forging and probably with good reason
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No stress analysis has been performed on the parts.
And you're right original ones are forgings. And my guess is that they were made from a not super uber hard steel, in order to be fatigue compliant, and not brittle.
The approach is the following:
Castings have the exact same dimensions, since the design is based on a 3d scan of a "real" one. All cross sections are then the same.
The alloy used is a high strenght chromoly, wich has the property to quench envenly in depth, and it is possible to chose in a relatively wide range of UTS.
Casting is less perfect than forging. Hence the parts will undergo 2 different heat treatments.
THe first one is clled Hot Isostatic Pressure. This treatment acts "like" a forging. It closes all the micro porosities in the part. Another side effect is to "anneal" the base metal. Hopefully grain size will grow, and be more even compared to a "as cast" parts.
Bigger grain size means lower caracteristics, but also has a good effect on toughness, and fatigue resistance.
Final heat treatment will give the parts its caracteristics. A medium UTS will be chosen for a good resilience, good fatigue resistance, and good caracteristics.
For information, the heat treatments alone are as expensive as the raw castings!
I am pretty confident the parts will be more than trustable.
Plus, I am not the first to make these parts in casting, and the feedback is good so far...
The steering levers will be billet machined in a lower grade steel, and hopefully in case of a small accident they will bend before the uprights.
Thank you for your input in this thread!
Olivier.