Motorsport Plumbing Systems: Fabrication
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Fabrication
04.30
| 00:00 | In this section of the course, we're going to leave the theory behind and look at all the practical skills we might need to master when building, modifying and maintaining our plumbing systems. |
| 00:11 | Let's start by looking at the general fabrication process. |
| 00:14 | Metal fabrication, including cutting, drilling, welding and an endless list of other processes are all skills that will be helpful to our plumbing endeavours, especially with the larger diameter piping like charge air intakes. |
| 00:28 | We aren't going to get too deep into the topics here as it's a broad subject that HPA's Fabrication Fundamentals course covers in detail. |
| 00:37 | This Fabrication Fundamentals course teaches you all the techniques and knowledge required to tackle motorsport fabrication, including everything you'd need when working with plumbing. |
| 00:48 | So, it's worth checking out if you're interested in a much deeper dive. |
| 00:52 | In saying that, let's discuss what those techniques are and where we would use them in our plumbing projects. |
| 00:58 | Taking our intake and charge air plumbing as an example, let's say we're working with aluminium piping, and we haven't just bought an off the shelf plumbing kit as our application requires something custom. |
| 01:10 | Besides the design and planning sides of things, we'll need to be able to cut the pipes to the lengths and angles we need. |
| 01:17 | This is ideally done with a cold saw rather than an abrasive cutting disc due to the contamination transferred into the material that will be an issue if we plan on welding the edge. |
| 01:28 | This is a much bigger issue with aluminium than ferrous materials. |
| 01:32 | In saying that, sometimes we need to use what's available to us and angle grinders, band saws or manual methods like hacksaws will all do the job. |
| 01:42 | Some masking tape around the pipe can also help us make a straight cut. |
| 01:46 | No matter what cutting method we use, we're more than likely going to want to weld the pipes together or weld on ferrules for pipe clamps. |
| 01:54 | And this means good preparation and cleaning is required for a decent result. |
| 02:00 | A combination of files, scouring pads and acetone go a long way here. |
| 02:05 | But we just need to be careful not to introduce other contaminants in the process. |
| 02:10 | While some welding is covered in the fabrication course, the best place to pick up these skills is in the HPA Practical TIG Welding course. |
| 02:18 | If you're interested in both of these courses, you should definitely look into our fabrication Starter Package which will save you a good amount of money. |
| 02:26 | Now, drilling holes to weld in bungs for sensors is another common process which could be done with a hand drill or in a drill press or potentially a mill where we can clamp the pipe in place and ensure we're drilling straight into the part. |
| 02:41 | A smaller hole will naturally be made with a sharp drill bit and step drill bits can be helpful as well. |
| 02:47 | But a larger hole will typically be made with a hole saw suitable for the type of material we're working with. |
| 02:53 | In some cases, we might need to tap threads into the holes for our fittings. |
| 02:59 | The material we're working with will determine how difficult this is. |
| 03:02 | For example, aluminium is fairly easy whereas stainless steel is a lot harder. |
| 03:08 | Just be sure to drill the correct size pilot hole first as you might find yourself scrapping the part in the worst case scenario. |
| 03:16 | Although not technically part of our plumbing, it's likely we'll also be bending, forming and working with sheet metal if we want to make any brackets to support our plumbing or components. |
| 03:27 | Sheet metal folders are great for thinner material, otherwise a press brake, punch and die and a hydraulic press will be suitable for thicker parts. |
| 03:36 | But again, it's possible to get some good results in the bench vice if that's what's available. |
| 03:41 | While all of this is going to require the use of various power tools and hand tools, the Fabrications Fundamentals course also includes a detailed look into safety considerations and PPE or personal protective equipment. |
| 03:56 | Iron air protection as well as gloves, aprons, overalls and boots should be worn whenever necessary. |
| 04:02 | It's just not worth the risk to save a few moments making sure you're protected. |
| 04:07 | Again, I highly recommend looking into the HPA Fabrication Fundamentals and TIG welding courses, as this will give you the knowledge and practical skills required to tackle the general fabrication involved in motorsport plumbing. |
| 04:23 | In the process, we'll be covering some more specific plumbing skills in the following modules. |
