smokenbaby 0 Report post Posted June 6, 2011 After a bit of experimentation vacforming a skin of ABS seems to be an excellent way of sealing the mdf mold. It in effect gives me both male or a female mold depending which side of the ABS i use. Also trying the first wet layup to see how it will work out. So far so good for a fiberglassing noob Hopefully the second half will get machined up soon. Let me know how this all works out and what you think the costs would be to make a second airbox. I am starting a very similar project for a mates rally car. Quote Share this post Link to post Share on other sites
DRTDVL 0 Report post Posted June 6, 2011 looking good matt! Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted June 8, 2011 Let me know how this all works out and what you think the costs would be to make a second airbox. I am starting a very similar project for a mates rally car. Will do, may depend on the option you would want ie just the box or with backing plate f-glass or carbon etc Will be able to be more specific once ive made this one looking good matt! Cheers Heath, want one for the puggy?.. Quote Share this post Link to post Share on other sites
DRTDVL 0 Report post Posted June 8, 2011 yes and my dash!@ Quote Share this post Link to post Share on other sites
smokenbaby 0 Report post Posted June 8, 2011 Will do, may depend on the option you would want ie just the box or with backing plate f-glass or carbon etc Will be able to be more specific once ive made this one Would be good as just with Glass. I would also like the backing plate with the trumpets. Cheers Quote Share this post Link to post Share on other sites
Apex Effects 3 Report post Posted June 8, 2011 Nice work matt progressing nicely Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted July 3, 2011 Second half of the mold completed today, had a few hicups on this one where the cnc decided to eat the part but came out in the end ok. As before i have skinned it in ABS as a mold sealant and release surface. As i was at it i pulled a couple of extra skins off and assembled them to establish part lines and create a prototype for mock-up. All in all quite chuffed with the result so far. Mdf molds back to back. The section in the middle between the lines and abs skin is part of the mold only and wont be present in the part. Completed prototype Entry downward facing Engine side. Most of this face will be replaced with a aluminium backing plate which will have the trumpets passing through it. The whole lot will be sealed and clipped together with overcenter style clips fitted into the 4 recesses. Quote Share this post Link to post Share on other sites
kerry 10 Report post Posted July 3, 2011 thats sweet man, good work. Quote Share this post Link to post Share on other sites
Apex Effects 3 Report post Posted July 9, 2011 Sweet prototype man! Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted July 19, 2011 (edited) 12:57pm Carbon fibre arrived this morning after 5 weeks from the US. At the time it was cheaper but since then its been popping up on trademe for the same price! At least it has now arrived. Also will be trying a different technique to mold the parts using cling film and a fridge compressor. More on that later if it works... Carbon spec 2x2 3k Twill. ADDED @ 8 PM Ok so couldnt wait till the weekend so i have decided to have a practice run. Here is a pic of the setup. Its a complete guess/seat of the pants experiment. Fridge compressor is providing vacuum to the bag to press the fiberglass together. A technique called vacuum consolidation so my second attempt at fiberglassing just went high tech, sort of.. Looks ok so far. Will have a final result in an hour.. Edited July 19, 2011 by MLM Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted July 19, 2011 Results: That worked out mint! The part pulled into all the nooks and crannies, cured and released perfectly from the mold. The inside finish is mirror like thanks to the ABS and the exterior is fairly smooth from the glad wrap. Nothing 10 minutes with sand paper wouldnt sort out. The excess around the edge will be cut away once fully hardened to reveal the final part. I may even use this one as a base for the carbon fibre. Quote Share this post Link to post Share on other sites
DRTDVL 0 Report post Posted July 19, 2011 NICE!!!!!!!!!! Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted July 20, 2011 Cheers Heath, Seeing as the inside came out with such a good finish im considering making a tool from the abs mold. More work and a bit more expence (maybe $100) but then i would have parts with the perfect finish on the outside where you want it. A shiny inside is a but arse about face. Plus the extra work would probably be saved in trying to make the outside perfect. Be a shame to go to all this effort and the have a part which looks average on the outside cos i couldnt be bothered. Quote Share this post Link to post Share on other sites
westy 614 Report post Posted July 20, 2011 NICE!!!!!!!!!! +me. Awesome. Quote Share this post Link to post Share on other sites
hybrid 1043 Report post Posted July 20, 2011 +2 .. loving the DIYP (Do It Yourself Properly) attitude Quote Share this post Link to post Share on other sites
Apex Effects 3 Report post Posted July 30, 2011 (edited) mint result man ^+1 on diyp Edited July 30, 2011 by GASTKR Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted July 31, 2011 Ok, so today is carbon day. Over the week I made a mold, which didn't end up costing anything as I had enough materials. The mold turned out to be quite testing of my patience but the end result was ok. From there I have now just completed the first (and my first) carbon layer. Damn this stuff is tricky to work with. No only is it harder to form into shape due to its greater stiffness but also if using it for cosmetic reasons like i am you need the weave to sit well. Not an easy thing. so my first attempt is good but not perfect. Im still happy though. Work area with second mold hooked up to fridge compressor vacuum pump Carbon in place. looks a bit ratty but will trim up ok Not perfect but pretty good weave layout. From here I will let it cure before adding more layers (1 carbon 1-2 glass). Then fingers crossed I will have a blingy carbon part which looks and functions well. Quote Share this post Link to post Share on other sites
Greg111 13 Report post Posted July 31, 2011 Very nice! You can make me one now Quote Share this post Link to post Share on other sites
hybrid 1043 Report post Posted August 1, 2011 Nice! .. Ive been looking into the flow dynamics of trumpets and internal (to the box) trumpet length .. Some interesting discussion around staggered lengths to circumvent vortext intruption due to firing order / backpressure of each cylinder. Also learnt that the air follows the walls of the trumpt and has a dead spot in the center. Mucking any of this up obviously causes power loss etc. I wish I was a bit more skilled with fluid dynamics software to even use it. Quote Share this post Link to post Share on other sites
Greg111 13 Report post Posted August 1, 2011 Nice! .. Ive been looking into the flow dynamics of trumpets and internal (to the box) trumpet length .. Some interesting discussion around staggered lengths to circumvent vortext intruption due to firing order / backpressure of each cylinder. Also learnt that the air follows the walls of the trumpt and has a dead spot in the center. Mucking any of this up obviously causes power loss etc. I wish I was a bit more skilled with fluid dynamics software to even use it. Playing with the trumpets is a big no no, they're tuned from factory the way they are, loss of power and torque will be inevitable. But you already no this Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted August 1, 2011 Done. Im reasonably happy with my first carbon part. Issues are the resin has cured with a slight cloudy white colour which is inconsistant. You can sort of see it in the picture. There are ways around this which i may try. For an underbonnet component though it hardly matters as it only really shows when light hits it the right way. Still noticable however which bugs the perfectionist in me. Quote Share this post Link to post Share on other sites
MLM 57 Report post Posted August 1, 2011 Nice! .. Ive been looking into the flow dynamics of trumpets and internal (to the box) trumpet length .. Some interesting discussion around staggered lengths to circumvent vortext intruption due to firing order / backpressure of each cylinder. Also learnt that the air follows the walls of the trumpt and has a dead spot in the center. Mucking any of this up obviously causes power loss etc. I wish I was a bit more skilled with fluid dynamics software to even use it. The more I learn about the fluid flow analisis the more realise how much is still best guess not absolute accuracy. Still, i believe that you can use intellegence and a bit of intuition to get better results. The discussions you mention would be good to be part of. Inlet length impacts torque, trumpets change effective length, taper angles are critical etc . Bit of a mine field really. I chose stagered trumpets in terms of location not length so the trumpet behind the leading trumpet is not drawing turbulent air created by that leading trumpet. In its shadow if you like. Analisis an logic says it should work.. Quote Share this post Link to post Share on other sites
Apex Effects 3 Report post Posted August 3, 2011 That LOOKS MINT even with the cloudyness to it. good stuff dude. Quote Share this post Link to post Share on other sites
mooseheadm5 0 Report post Posted August 12, 2011 Pretty amazing stuff there! I signed up just to watch this topic. Quote Share this post Link to post Share on other sites
kingkarl 136 Report post Posted August 12, 2011 Done. Awesome Quote Share this post Link to post Share on other sites
