Help me design a carbon fiber intake manifold.

[Crazy_pilot]

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.

[Stevebsy]

Originally Posted by Crazy_pilot

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.

What Resin are you thinking of using? There are bagging/bladder materials that will take the high temp so that shouldn't be much trouble.

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.

[Crazy_pilot]

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.

[svxfiles]

Originally Posted by Stevebsy

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.

Normally the intake manifold does not go over 200°f, even in the summer on a 100°f day.












MMMmmmmmmmmmm, 100°f day!

[Johnybeas]

Interesting project. Can't wait to see the results.

[Crazy_pilot]

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.

[Cam]

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.

[svxfiles]

HMmmmmm, can you whip up a carbon fibre 4.0 H-6 block?


I'd trade you my soul for it.

[Hocrest]

Originally Posted by svxfiles

HMmmmmm, can you whip up a carbon fibre 4.0 H-6 block?


I'd trade you my soul for it.

Wow!!!! Talk about a lopsided deal

[Crazy_pilot]

Originally Posted by Cam

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.

That's the idea. The flanges are all going to be anodized gold to match my BBS wheels.

Originally Posted by svxfiles

HMmmmmm, can you whip up a carbon fibre 4.0 H-6 block?


I'd trade you my soul for it.

I'll get right on that.

[Johnybeas]

Originally Posted by svxfiles

HMmmmmm, can you whip up a carbon fibre 4.0 H-6 block?


I'd trade you my soul for it.

+1.... papapalease??? hahahahah

[svxfiles]

Originally Posted by Hocrest

Wow!!!! Talk about a lopsided deal

Like anyone HERE would believe that I actually HAD a soul!

[svxfiles]

Originally Posted by Crazy_pilot

I'll get right on that.

REALLY?!

OK, Great, got my soul right here,,,its never been used,,,
I'll keep it in a box for ya,,,









TEEHEEHEEHEE, snort!

[httrdd]

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!

[Stevebsy]

Originally Posted by Cam

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.

Ditto on the anodizing, very necessary to have some sort of coating inbetween the CF and the Aluminum.

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!