Using a high temp (600*) metal filled epoxy I bonded standoffs for the mounting bolts to the base and began shaping floral foam contours of the interior for each runner
once I was happy with the shape I covered the foam in clear silicon caulk to seal it (floral foam is porious and soaks up the resin/epoxy) and to smooth out the surface
since my design had to split in half in order to bolt to the engine I cut a seal in it and cut the forms out for the bolt hole locations.. these when filled provide a thick mounting boss on both halves as you will see later
once I had finished smoothing the bottom half I wrapped it in plastic wrap and placed the top halfs foam core ontop and began glassing it in also
on the top I added micro ballons to the mixture, for those not familiar with that name the micro balloons are a filler material of tiny hollow glass spheres so light they allow resin to float in water.. I did this just to add more rigidity without weight
lets see.. about an hour a night for two weeks - so say 10 hours
Oh i forgot to add cost of materials.. thats about 120$ in epoxy, 15$ in fiberglass, and aluminum plates out of the scrap bin at work, and about 5$ in stainless metric socket head bolts. So a high flow intake for under 150$
[This message has been edited by Kohburn (edited 12-09-2005).]
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10:34 AM
Fie Ro Member
Posts: 3735 From: Soest, The Netherlands Registered: Sep 2001
Very nice, I thought for a minute you were going to cast it from aluminum, but very nice work nonetheless.
actually I've though about making molds from high temp ceramic resin (good to 4000*) and selling cast aluminum copies - but I want to tune it and dyno it before i go that far
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11:33 AM
ryan.hess Member
Posts: 20784 From: Orlando, FL Registered: Dec 2002
looks awsome! great use of composite materials. what did you use for bolt bosses in yhe upper cover to lower mounting screws if you don't mind saying? i am giving you a plus cause i like composites and homebrewed intake manifolds.
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08:42 PM
Alex4mula Member
Posts: 7403 From: Canton, MI US Registered: Dec 1999
Wow! That looks... mmm... kind of weird like a pill but nice.
Ok, now I know. Don't you think it looks like a fire extinguisher? Specially last pic. Paint it blue and will look like NOS bottle But don't take me wong. I admire the labor you did to get it done. I know is lost of work. And I agree it looks much better than that square box.
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09:11 PM
F-I-E-R-O Member
Posts: 8410 From: Endwell, NY Registered: Jan 2005
Whenever I see flames in the engine bay, I get a little nervous... (looks like flames on top) I think it looks awesome. Let us know when you start selling the completed version!
WOW! That's some inventive work! Looks great painted and on the engine!
------------------ Bob Williams Multi-colored '86 Mutt, a work in progress! (3800SC running great! Fixed the bent roof, now I need an intercooler! Yeehaa!)
So Koburn, where's the one for my engine? Seriously though, i hope this works and that you make some for other people. Be nice to have another aftermarket power enhancer for the TDC. Now if someone would only make headers....Non Aaron ones.
So Koburn, where's the one for my engine? Seriously though, i hope this works and that you make some for other people. Be nice to have another aftermarket power enhancer for the TDC. Now if someone would only make headers....Non Aaron ones.
you are gonna hafta wait for my tuning and yno results - I would never sell anything that was not tested
you are gonna hafta wait for my tuning and yno results - I would never sell anything that was not tested
Oh most definitely I agree. I figure if it works for you, not only will that be great to see you succeed but it would also mean that you'd most likely sell it to others which would help them as well. Id like to see this engine continue to gain aftermarket support. It really needs guys like you who can make things like this. You seem to me like a guy who, if this design doesnt work, will go back and try again. Your timing tool has already made things better for everyone and i hope this intake does the same.
Originally posted by Dave Gunsul: Oh most definitely I agree. I figure if it works for you, not only will that be great to see you succeed but it would also mean that you'd most likely sell it to others which would help them as well. Id like to see this engine continue to gain aftermarket support. It really needs guys like you who can make things like this. You seem to me like a guy who, if this design doesnt work, will go back and try again. Your timing tool has already made things better for everyone and i hope this intake does the same.
well i may end up being selfish with the intake.. however the next project is making the cam cogs adjustable just like aftermarket ones..
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01:50 PM
Feb 27th, 2006
Erik Member
Posts: 5625 From: Des Moines, Iowa Registered: Jul 2002
I think it looks awesome. Let us know when you start selling the completed version!
