Merc, the short answer is I’m not in a position to take it on at this time. The longer answer for other’s curiosity……
…..I did do the CAD work, and I can easily manipulate the model. The model in the picture is actually a CNC machining out of nylon, about 5 pieces and glued together. That route was just as cost effective as a 3D print.
Those are all the steps I would use to produce the polystyrene pattern. You represent a unique subset of people that make casting inquiries of me being you not only have a solid model, it has been used and presumedly produced a gcode file to cut the pieces. Most people that approach me do so with a loose description or a “looks like” picture. The reverse engineering of all the dimensional and feature data for a new engine family is a big effort that is rarely done accurately enough by the uninitiated. I’ve learned some hard lessons relying on data provided by others. You on the other hand have design validation.
……I will get the dimensions and volume when I get home later. I found a company that can 3D print sand molds for a "reasonable" amount. I just haven't had the time to talk to a local foundry to see if they would be willing to pour with a 3D printed mold.
The reason I asked for that dimension is I suspect it’s too large for my present casting flask (<16” diameter), so even if I was inclined to cast it, I’d have to make a larger molding rig, which although not out of the question, I wouldn’t be inclined to do so at this time. I also think it becomes just a little too large for me to machine because of available height under quill with the fixture on my mill. I asked for volume to estimate casting weight. Blower intakes get a bit chunky. Right now I can pour <60lbs include sprue/gating…….I suspect this part is still well within reach of that.
……I went into this wanting to make one for my self as the old Weiand intake that I also have are race only pieces and not street friendly. As pbf777 indicated, there is probably a total available market for about 5 or 6 of them.
You mentioned sand prints. I suspect you already know all I’m about to say, but for those considering things like this, there should be no reason to source the casting separately. Not sure who Jay uses but Hoosier pattern for instance will deliver you a heat-treated casting from your solid model. Last I checked, they had one-time charges for CAD related mold mods of $750-$1000, and foundry charges of $750. Then you pay for the (each) mold by the cubic inch, which for parts like this could be in $1500-$2500 range.
With the quality of your model, you may do better on the CAD charge and if you were to procure multiples, the economics improve considerably, but at the end of the day, you’ll get a raw casting, and I mean raw.
Attached is a photo of an example an acquaintance did with them within the last year. He did a ton of finish work on the exterior of the casting. Though it isn’t terrible, neither I nor any of my typical customers would ever except it as delivered, and spending days with burrs and cartridge roles isn’t on my bucket list.
My casting process yields far better fit and finish, comparable or better to quality aftermarket castings. Other than light media blast, the casting pictured in my original post is as it came out of the mold. Although I do charge, I do this as a hobby, but mostly because I enjoy engineering the turn key induction system because it’s fun, interesting, and keeps me current by exercising many disciplines, and I meet some great people. Repetition becomes work and I can assure you, I didn’t retire to become a short run foundry. Even if you were to get one from me, you’d never get five.
Best,
Kelly
