OK... A lot going on at Redneck Engineering (AKA Brown Injection Systems). We are introducing and shipping a new type of throttle body that is cast aluminum. The crazy part was I didn't know anything about casting so during the supply shortage, I got into casting. I learned initially how much I didn't know and a barefooted Indian on youtube can make you look like an idiot.

After experimenting with every type of casting process for a couple of years, I had to best luck with lost foam casting. So much so, that I bought a small CNC and cut the throttle body tops out of foam, and then pour them in aluminum. Are they as nice as $250 a piece billet TB, NO... but then how much fun is that. I bought a metal forge and set it up at my brother's farm. This has also gotten him involved with casting and Corvairs, so I slowly sucked another one in.

One phone call can change your life: Got a call in Sep 2022 and in Jan of this year we took a foster baby girl with the goal being adoption. I blame my children because they are too selfish to give me grandkids. We are still in DSS hell, so that will last until we get her adopted. I'm 60, so I made a deal with my doctors that if they would do their job, I would do mine. No pics until she is adopted (DSS rule).

Now that my life has changed, my schedule has too, but I still plan to continue to make EFI kits and stay heavily involved in the Corvair hobby. This leads now to the next thing... for years I wanted to make individual heads for the Corvair (similar to aircraft engines) but like everyone else, the CNC machines, knowledge, and money usually stops that. Now that I am casting aluminum with pretty high confidence, I am back on that crazy kick. I know there is a lot more to it (hardening, etc), but right now I want to do something.

Raceguy2 was on here a couple of years ago getting ready to cut a billet head and then kind of fell off the earth. Has anyone has any contact with him? If I could get his DWG or STL file, I can cut out of foam and start down that path. Included are a couple of pics of the throttle bodies that we are casting...the 2nd pic has the foam and aluminum side by side.

Ted

2 & 4TBI units are available through Corvair-EFI.com
Ted Brown
Anderson, SC
Brown Injection Facebook
65 Monza Convert 140 4 Speed - EFI
68 Monza Convert Auto - EFI (Undergoing Resto)
63 Greenbrier 4 Speed - EFI (Daily Driver)
61 Loadside 2.9L - PGlide - EFI (Driveway)
61 Rampside - 4 speed - EFI
61 Greenbrier 4 speed - EFI
61 Greenbrier 4 Speed - Bad Motor
64 Monza 4 Speed - EFI
63 Monza Convert 3 Speed Carbs

Nice!

Frank DuVal

Fredericksburg, VA

Very nice, a bit of glass beading and that would shine up nicely.

1966 Monza Convertible, 140HP-4 speed, Ermine White
1969 Monza Convertible, 110HP-PG, Frost Green, #3753

Black Mountain,NC

Others in the menagerie...
72 Corvette Stingray, 58K miles, owned since 87
72 MGB, 112K miles, bought from original owner in 09
78 Chevy pickup, 124K miles, bought new in 78
93 Corvette, LT1/6spd, 210K miles, daily driver since 96
02, Chevy Z71, 4x4, 93K miles, my Dad's truck, inherited 2021

Wow!

I wish I would have stayed with playing with foam! Cool stuff!!

Adoption is great! My wife would tell them 'Not born of my womb, but born from my heart'. We had a great experience with it.

Doug
65 Monza
Cincy, OH

Cool!!

I think you should be hailed as a super person. I had just discussed this with my doctor yesterday at the VA...but I said I am too old and she said I have lot to offer and I should mentor young people, they are starving for knowledge.

PM sent

Good luck on both your efforts.

Jimc
1965 Corsa Coupe, two owner history


HACOA Member
CORSA 2017 Concours Senior Gold Award
AACA 2015 Award

Vairy cool stuff, Ted!

So, is the development/finalization of the FC turn signals on the back burner now?

Dean F. Gemberling
Columbus, Georgia
Heart of Georgia Corvair Club Webmaster
Springfest Webmaster

1963 Rampside w/305 V8 - Built by Ken Arnold in 1998
1965 Monza Coupe - Converting from Drag Race Car to Nice Street Car - 63 Buick 215 V8

jimc Wrote:
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> PM sent
>
> Good luck on both your efforts.


Second this. Brave beyond belief

Dan Central MN
1968 Convert

Hi Ted, while you are sorting out the design of the new cylinders, I think it would be a great leap forward if you could develop a threaded in valve seat with locking set screws. We in the Corvair world would probably embrace that idea with enthusiasm. Doug Ward

Doug Ward
Orange, Calif.
65 Corsa 180, 64 Monza convertible, 61 Lakewood, 61 Monza

This has been done years ago

That doesn't look like a lost foam casting to me.

Joel
Northlake, TX
5 Ultravans, 145 Corvairs and counting...

solo2r Wrote:
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> This has been done years ago

Don't even know how to respond to that.

Ted

ihscomputers Wrote:
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> Vairy cool stuff, Ted!
>
> So, is the development/finalization of the FC turn signals on the back burner now?

One thing about it, when I dig those drawing out and put that print together, you are the first on the list.

Ted

I still plan to develop this single-cylinder head design but was hoping the fellow that was doing the billet had a file...I'm even will to pay for it as it would cut out hours of design and drawing time.

Now that I have to stay alive until I'm 81, I have plenty of time.

Ted

TedBrown Wrote:
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> solo2r Wrote:
> -------------------------------------------------------
> > This has been done years ago
>
> Don't even know how to respond to that.
>
> Ted


Ted,

Charge on full speed with your great work. There is always one naysayer, regardless of the car forum....

Will we see you at Helen GA? Loved your EFI conversion at Peachtree City last year.

Mike

1966 Monza Convertible, 140HP-4 speed, Ermine White
1969 Monza Convertible, 110HP-PG, Frost Green, #3753

Black Mountain,NC

Others in the menagerie...
72 Corvette Stingray, 58K miles, owned since 87
72 MGB, 112K miles, bought from original owner in 09
78 Chevy pickup, 124K miles, bought new in 78
93 Corvette, LT1/6spd, 210K miles, daily driver since 96
02, Chevy Z71, 4x4, 93K miles, my Dad's truck, inherited 2021

You don't respond to that. You continue doing the great work we all appreciate. Great news on the new addition to the family!

Bless you, bless you and bless you for adopting that precious child!!

Gregg Birkholz
Canaan, CT.

1967 Monza 110 PG Convertible
2013 Chevy Malibu (Wife's DD)
1993 Cadillac Deville
2012 GMC Sierra 1500 Crew Cab
1997 Mazda Miata STO (Wife's fun car)
1989 Cadillac Deville (parts car)
2008 Buick LaCrosse (DD)

your site says you have also been looking at building a FI system for turbo engines.

I will be watching for that

jfreez Wrote:
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> your site says you have also been looking at building a FI system for turbo engines.
>
> I will be watching for that

The system has been designed/built and waiting on the installation of the motor in the doner car. Should happen within the next 2 weeks. I will post a new thread when we get that far. We are going to use straight injection first, then possibly add staged injection (3rd injector) if we see a lean situation.

Ted