markrolston@mac.com Posted June 22, 2012 Author Share Posted June 22, 2012 Hey Mark, I was looking at how to model an intake, and This is what I came up with. Of course it would take a bit more tweaking. I was using the PTC Creo Elements (FREE VERSION!) to make the model. I spent maybe an hour kludging this one together. here's the files as it stands: Intake design.zip You may not be interrested in going this way especially because printing something like this would have some challenges due to the size. (Mainly having to slice and glue.) Though a lot could be done on the design side internally and it would hardly look like it wasn't a single piece since tolerences would be tight. Phar 3D printing certainly is an option but to make it a CF part means I need to be able to remove the material once it's wrapped, and the printer plastic would not be so easy to extract. The foam is relatively easy to remove. I am also integrating interior aluminum horns, which is why there is an aluminum plate on the inner side of the plenum. Quote Link to comment Share on other sites More sharing options...
itzgoten Posted June 24, 2012 Share Posted June 24, 2012 Mark, Kind of late but it's nice to find your build on here. I've been checking in on your blog for years but the updates are somewhat random (time wise) where this is very frequent. Wish I had found this sooner. Love the new build! Quote Link to comment Share on other sites More sharing options...
Pharaohabq Posted June 24, 2012 Share Posted June 24, 2012 Mark, Not a problem, I was just thinking this might be another way to make things. My drawings were just an example, but 3d printing could make the plenums and integrate the horns as well, though you're right, The CF would not be so easy to do. Certainly it's your project so however you're want ing to do it is your choice. I was just trying to make suggestions. I love what you've been doing, and if I had the time and budget, my HR build would be much nicer than it is. Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted July 9, 2012 Author Share Posted July 9, 2012 some small progress on the plenum. foam now covered in clay. Symmetry was (as predicted) a b!tch to get right. Next step is carbon fiber. Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted July 9, 2012 Author Share Posted July 9, 2012 (edited) some really cool news to share as well- one of the guys in my studio has a long history in the automotive industry (he was the project leader for the Porsche GT) and he shared my plenum design with the Ferrari engine design team just to get some advice (good friends to have!). I got word back this week that they think the plenum design looks just right for the engine and it's purpose. Kinda cool to get the thumbs up from such esteemed sources. Edited July 9, 2012 by markrolston@mac.com Quote Link to comment Share on other sites More sharing options...
Pharaohabq Posted July 9, 2012 Share Posted July 9, 2012 NICE! that's pretty cool. Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted July 10, 2012 Author Share Posted July 10, 2012 first layer of CF. Quote Link to comment Share on other sites More sharing options...
MazerRackham Posted July 10, 2012 Share Posted July 10, 2012 Oh my gosh. Your on Hybridz. I have to say I've watched your 240z YouTube video one too many times. This second carbon fiber one is absolutely gorgeous. Quote Link to comment Share on other sites More sharing options...
Pharaohabq Posted July 10, 2012 Share Posted July 10, 2012 Looks pretty nice. Uhm... I know stupid question, but how do you get the clay and foam out w/out cutting the pretty CF up? oh wait! the metal where the intake tubes will come off right? How many layers of CF are you going to use? I imagine you'll need a few since your turbos will be pushing 15-20 psi right? Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted July 11, 2012 Author Share Posted July 11, 2012 Looks pretty nice. Uhm... I know stupid question, but how do you get the clay and foam out w/out cutting the pretty CF up? oh wait! the metal where the intake tubes will come off right? How many layers of CF are you going to use? I imagine you'll need a few since your turbos will be pushing 15-20 psi right? at least 3 layers cold and bagged. likely 4. then we cook the assembly in an oven to cure them above engine operating temps. That makes the material stable at those temps. Then one more layer for aesthetics. It'll hold way more pressure than what turbos can produce. yes, pull the aluminum flanges and the internal foam and clay is accessible. not too hard. internal walls will be smooth. then those flanges will be welded to the tubes and horns and the assembly bolted back to the CF plenum body with a gasket seal. The inlet has an aluminum tube so we can weld a flange to this to bolt on the TBs. Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted July 25, 2012 Author Share Posted July 25, 2012 Plenum is coming along. Here are the parts before we pull the foam out and add one more layer of CF for cosmetics. Also, oil tank is installed and intercooler core just arrived. Quote Link to comment Share on other sites More sharing options...
MazerRackham Posted July 25, 2012 Share Posted July 25, 2012 This car is obscene. So Good. Quote Link to comment Share on other sites More sharing options...
Pharaohabq Posted July 30, 2012 Share Posted July 30, 2012 Okay, I think you've convinced me that I need to go learn to do Carbon fiber moulding. your CF looks awesome. Those plenum are going to be so pretty connected to the turbos. Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted August 2, 2012 Author Share Posted August 2, 2012 The oil sump position all the way in back meant the lines were too long. It will now be on the passenger side in the engine bay. The plenum is coming along. Here's a first shot of how it will sit atop the engine. Lastly the diff is now installed. Up next is the finished plenum, intercooler, radiator, and turbo plumbing. Quote Link to comment Share on other sites More sharing options...
rp975 Posted August 3, 2012 Share Posted August 3, 2012 Very cool, love watching this build, it is so amazing, well done again. Rob Quote Link to comment Share on other sites More sharing options...
MrKrispy1183 Posted August 3, 2012 Share Posted August 3, 2012 I am awestruck and simultaneously deeply saddened every time I see progress on this monster (saddened only because I can only dream to replicate anything remotely as exquisite). More!!! Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted August 3, 2012 Author Share Posted August 3, 2012 (edited) Thanks. It's been a long haul- 4 years and another year to finish. Here's a quick mockup of where I'm headed. It's just a rough render and the TBs are not included. Edited August 3, 2012 by markrolston@mac.com Quote Link to comment Share on other sites More sharing options...
RB26powered74zcar Posted August 3, 2012 Share Posted August 3, 2012 Stunning! Quote Link to comment Share on other sites More sharing options...
Pharaohabq Posted August 3, 2012 Share Posted August 3, 2012 looks really nice, How's your hood clearance? In that position will you have room to be able to pull out an ignition coil if you need to replace a plug? with the Irridium you shouldn't often have to but I don't know how well it'll run w/ the turbos. It's looking awesome though. Will the intake tubes before the TB's come up straight from the Turbos? With the depicted width I'm not sure of the angles and clearance for your belts / turbos at the front of the engine. Quote Link to comment Share on other sites More sharing options...
markrolston@mac.com Posted August 4, 2012 Author Share Posted August 4, 2012 (edited) looks really nice, How's your hood clearance? In that position will you have room to be able to pull out an ignition coil if you need to replace a plug? with the Irridium you shouldn't often have to but I don't know how well it'll run w/ the turbos. It's looking awesome though. Will the intake tubes before the TB's come up straight from the Turbos? With the depicted width I'm not sure of the angles and clearance for your belts / turbos at the front of the engine. Hood clearance is tight but we trimmed the tops of the original foam plenum mold to clear the hood so any further shaping would still fit within. The plenums are completely clear of the coils. The turbos are on the sides of the engine (see older pic) and so the charge pipe runs low and forward to the intercooler, then out of the intercooler straight into the TBs as shown in the mockup render. And yes, it'll all clear the belt assembly easily. The whole engine bay is pretty open and easy to package within since there are no inner fenders to contend with. Edited August 4, 2012 by markrolston@mac.com Quote Link to comment Share on other sites More sharing options...
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