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Thread: Porsche 906 under construction...+1

  1. #101
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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

    mms_20160126_140757.jpg

    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):

    DSC08044 - Copie.JPG

    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.

  2. #102
    Senior Member
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    Very cool part Olivier! Here are a few more photos of that Magnesium 906 gearbox casting.

    906 Carrera 6 Gearbox Case Mag Repro - Photo 01.jpg

    906 Carrera 6 Gearbox Case Mag Repro - Photo 07.jpg

    This one was listed at $21,000 on eBay back in Sep 2013...

    ERASE 2016-01-27_8-48-32.jpg

    ...and no clue on what the current market price-range for once of these completed could be.

    ERASE 2016-01-27_9-01-11.jpg

    Received these beauties from Germany this week.

  3. #103
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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

  4. #104
    Has a stress analysis been performed on the front uprights? The Porsche ones were a forging and probably with good reason

  5. #105
    Senior Member
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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.

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