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#16
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Re: Help me design a carbon fiber intake manifold.
I've thought about that too, using an inflation bladder, but the problem again comes when I need to bake the layup. Every part of the mold and bladder would need to be able to stand up to 350 degrees or more, and making the mold out of a heat resistant material instead of whatever I happen to have at hand would up the cost significantly.
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Chris 92 Ebony Mica LS-L "A Rolling Restoration": 223,250 KM - Sleeping 2007 STi 6MT, Stance GR+ coilovers, PWR Rad, JDM hood badge, svxfiles 6000K HIDs, JDM Clear Corners, $15/15 min mod, $20/20 min mod, Energy Swaybar Bushings, Hella Supertones horns, Gold STi BBS rims, Group A lightweight crank pulley, A/C system removed, Custom header-back exhaust, Hybrid carbon/metal rear sway bar, restored headlights with CCFL halos 2008 Subaru Legacy Spec B - Diamond Grey Metallic - Sold 2020 Ram 1500 Longhorn - Red Pearl |
#17
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Re: Help me design a carbon fiber intake manifold.
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Just curious, have you (or anyone else) measured the actual temp of the intake under operating conditions? That could help you pick the right resin system.
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'93 Anniversary Edition SVX 122k - 3.7 FD 5MT Swap, ECUtune 1a1, Bontrager RSB, Mad Restoration underway! '20 Honda Ridgeline Custom Oil Caps, Battery Bars, Phenolic Spacers for sale here: http://www.x35design.com |
#18
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Re: Help me design a carbon fiber intake manifold.
I've been exchanging e-mails with Aircraft Spruce, who have suggested De-Comp's HT212 system (link). It has a 290*F distortion temperature and some flexibility (better vibration resistance vs uber-rigid/brittle stuff).
I probed my engine with an IR thermometer before I parked the car for the winter and the highest temp I could find, short of aiming it at the exhaust, was 92*C (198*F), so I think 225*F is a good starting point for my epoxy search.
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Chris 92 Ebony Mica LS-L "A Rolling Restoration": 223,250 KM - Sleeping 2007 STi 6MT, Stance GR+ coilovers, PWR Rad, JDM hood badge, svxfiles 6000K HIDs, JDM Clear Corners, $15/15 min mod, $20/20 min mod, Energy Swaybar Bushings, Hella Supertones horns, Gold STi BBS rims, Group A lightweight crank pulley, A/C system removed, Custom header-back exhaust, Hybrid carbon/metal rear sway bar, restored headlights with CCFL halos 2008 Subaru Legacy Spec B - Diamond Grey Metallic - Sold 2020 Ram 1500 Longhorn - Red Pearl Last edited by Crazy_pilot; 01-28-2011 at 11:07 PM. |
#19
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Re: Help me design a carbon fiber intake manifold.
Quote:
MMMmmmmmmmmmm, 100°f day!
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www.svxfiles.com The first SuperCharged SVX, the first 4.44 gears, the first equal length headers, the first phenolic spacers, the first Class Glass fiberglass hood, the first with 4, 4.44s in his driveway Fiberglass Hood thread My locker 4.44 Swap link |
#20
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Re: Help me design a carbon fiber intake manifold.
Interesting project. Can't wait to see the results.
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#21
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Re: Help me design a carbon fiber intake manifold.
Bit of an update. I spent a bunch of time in the machine shop today turning billets of aluminum into piles of chips, and MDF into sawdust. The results, 2 MDF molds to make the plenums, 2 flanges that will bolt to the injector stacks (one attached in the pictures), and a flange that will allow the throttle body to bolt on:
And the big beast that helped this all happen: I have 3 yards of twill weave carbon sitting beside me and a gallon of PTM&W 2520 epoxy, which has a service temperature rating of over 300*F. In the mail currently is 5 yards of 2" braided carbon sleeve to make the runners. (No pictures of the jig to make those, but it's ready) This weekend will involve sealing and prepping the molds. Lay-up to commence next week.
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Chris 92 Ebony Mica LS-L "A Rolling Restoration": 223,250 KM - Sleeping 2007 STi 6MT, Stance GR+ coilovers, PWR Rad, JDM hood badge, svxfiles 6000K HIDs, JDM Clear Corners, $15/15 min mod, $20/20 min mod, Energy Swaybar Bushings, Hella Supertones horns, Gold STi BBS rims, Group A lightweight crank pulley, A/C system removed, Custom header-back exhaust, Hybrid carbon/metal rear sway bar, restored headlights with CCFL halos 2008 Subaru Legacy Spec B - Diamond Grey Metallic - Sold 2020 Ram 1500 Longhorn - Red Pearl Last edited by Crazy_pilot; 03-17-2011 at 12:00 AM. |
#22
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Re: Help me design a carbon fiber intake manifold.
Very nice work on the aluminum pieces. Mold looks promising as well. Very nice progress.
I recommend anodizing for the aluminum parts. One of the things that happens between aluminum and carbon fiber is, since they are dissimilar materials, they will corrode. More specifically the aluminum will corrode. You will effectively stop this if you anodize the part and/or paint the mating surfaces between the stacks and the plenum. Otherwise your beautiful machine work will be for nothing. Aluminum and Steel, Aluminum and Titanium, CFRP (carbon fiber reinforced plastic) and any of the above can all cause corrosion simply from small amounts of moisture between the parts.
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Cam '92 Ls-L Dark Teal 11:1 CR ECUTUNE pistons ECUTUNE .256 duration intake/exhaust cams ECUTUNE STAGE 2AV1 ECU Z32 MAF/SR20DET injectors Balanced & Blueprinted |
#23
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Re: Help me design a carbon fiber intake manifold.
HMmmmmm, can you whip up a carbon fibre 4.0 H-6 block?
I'd trade you my soul for it.
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www.svxfiles.com The first SuperCharged SVX, the first 4.44 gears, the first equal length headers, the first phenolic spacers, the first Class Glass fiberglass hood, the first with 4, 4.44s in his driveway Fiberglass Hood thread My locker 4.44 Swap link |
#24
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Re: Help me design a carbon fiber intake manifold.
Wow!!!! Talk about a lopsided deal
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Dave - 03 Baja - 92 SVX - 86 Brat - 08 OB 3.0 |
#25
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Re: Help me design a carbon fiber intake manifold.
Quote:
I'll get right on that.
__________________
Chris 92 Ebony Mica LS-L "A Rolling Restoration": 223,250 KM - Sleeping 2007 STi 6MT, Stance GR+ coilovers, PWR Rad, JDM hood badge, svxfiles 6000K HIDs, JDM Clear Corners, $15/15 min mod, $20/20 min mod, Energy Swaybar Bushings, Hella Supertones horns, Gold STi BBS rims, Group A lightweight crank pulley, A/C system removed, Custom header-back exhaust, Hybrid carbon/metal rear sway bar, restored headlights with CCFL halos 2008 Subaru Legacy Spec B - Diamond Grey Metallic - Sold 2020 Ram 1500 Longhorn - Red Pearl |
#26
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Re: Help me design a carbon fiber intake manifold.
+1.... papapalease??? hahahahah
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#27
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Re: Help me design a carbon fiber intake manifold.
Like anyone HERE would believe that I actually HAD a soul!
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www.svxfiles.com The first SuperCharged SVX, the first 4.44 gears, the first equal length headers, the first phenolic spacers, the first Class Glass fiberglass hood, the first with 4, 4.44s in his driveway Fiberglass Hood thread My locker 4.44 Swap link |
#28
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Re: Help me design a carbon fiber intake manifold.
REALLY?!
OK, Great, got my soul right here,,,its never been used,,, I'll keep it in a box for ya,,, TEEHEEHEEHEE, snort!
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www.svxfiles.com The first SuperCharged SVX, the first 4.44 gears, the first equal length headers, the first phenolic spacers, the first Class Glass fiberglass hood, the first with 4, 4.44s in his driveway Fiberglass Hood thread My locker 4.44 Swap link |
#29
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Re: Help me design a carbon fiber intake manifold.
That soul comment reminded me of spongebob when mr krabs has a line of people with IOUs waiting for his soul. Is it the same for you too? Anyways carry on!
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#30
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Re: Help me design a carbon fiber intake manifold.
Quote:
Seal those molds really really well. MDF will suck in whatever sealant you apply. Shellac works pretty well. If you do not seal it really well, then you will be chipping the mold off of your part I have learned this the hard way a couple of times unfortunately... Also..I hope you put some draft angle into those molds What will you use for your mold release? I'll be interested to see how you are doing the runners. Looks good so far!
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'93 Anniversary Edition SVX 122k - 3.7 FD 5MT Swap, ECUtune 1a1, Bontrager RSB, Mad Restoration underway! '20 Honda Ridgeline Custom Oil Caps, Battery Bars, Phenolic Spacers for sale here: http://www.x35design.com |
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