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Discussion Starter · #1 ·
Found a easy place for hosting pic's so here is one of the Carbon fiber 3.5" intake I made for my V1. Keep in mind this was my first time making a carbon fiber part.
So wait till you see how nice my intercooler comes out. 2.5" mandrel bent Aluminum tubing polished like crome..
1/2" bar and plate core that will be 14"x8"x5" air/air..




Modified by Scooter98144 at 7:54 AM 2-12-2004
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (Scooter98144)

Hi,
This thing looks RAD!
can I see a picture of wherever the seam is on this thing? Secondly, how smooth is the INSIDE??
I have done a number of wet and prepreg carbon layups while I worked for a race team. I have been wondering how you would do a good intake without the inside of the tube being too rough or visible seams running the length of the tube--I have never seen either close up.
Thanks,
Andrew
 

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Discussion Starter · #3 ·
Re: Carbon fiber is cool My intercooler will be just as SWEET.. (bluecoast)

Well there is no seem. It is smooth inside. What I did was take PVC elbows and I cut and shaped them. Then I laid bondo over them to get good even flow and a full 3.5 from end to end as well as making sure it would fit. After the mold was perfect I masked it and laid one layer over the entire mold. Then I cute down each side and took that one layer off. Then I taped the two halves back together and laid 3-4 more layers of 10.5oz twill weave carbon fiber over those to halves and hence there is no real seam to be seen. Sand smooth and clear coat with resin then polish. I now have the mold to make a second one but I wana do an intercooler first.
VERY VERY strong yet weighs nothing.
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (Scooter98144)

Dude thats really sweet. Where did you learn to do that and get the material??

Cant wait to see the intercooler. Man I wonder how good that would be as turbo boost tubes. Would prolly be expensive but I bet it would look really cool. Nice work
http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (Scooter98144)

Quote, originally posted by Scooter98144 »
Well there is no seem. It is smooth inside. What I did was take PVC elbows and I cut and shaped them. Then I laid bondo over them to get good even flow and a full 3.5 from end to end as well as making sure it would fit. After the mold was perfect I masked it and laid one layer over the entire mold. Then I cute down each side and took that one layer off. Then I taped the two halves back together and laid 3-4 more layers of 10.5oz twill weave carbon fiber over those to halves and hence there is no real seam to be seen. Sand smooth and clear coat with resin then polish. I now have the mold to make a second one but I wana do an intercooler first.
VERY VERY strong yet weighs nothing.

Excellent execution my friend! http://****************.com/smile/emthup.gif
Reminds me of my forays into carbon fibre in college, though I do prefer kevlar in automotive applications. Have you though of using foam to mold the end tanks out of on the intercooler and lay the skin over the foam and intercooler ends at the same time to bond the end tanks and intercooler together? When the tanks have cured use some gasoline to melt out the styrofoam and voila. http://****************.com/smile/emthup.gif
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (Disco_Potato)

Quote, originally posted by Disco_Potato »

Excellent execution my friend! http://****************.com/smile/emthup.gif
Reminds me of my forays into carbon fibre in college, though I do prefer kevlar in automotive applications. Have you though of using foam to mold the end tanks out of on the intercooler and lay the skin over the foam and intercooler ends at the same time to bond the end tanks and intercooler together? When the tanks have cured use some gasoline to melt out the styrofoam and voila. http://****************.com/smile/emthup.gif

what kind of foam do you use that the resin does not eat through? and where can i get some?
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (blackbunny)

Quote, originally posted by blackbunny »

what kind of foam do you use that the resin does not eat through? and where can i get some?

Closed cell polypropeleyne, I need to look up a supplier though. Should be availible at aircraft supply houses like Aircraft Spruce, that is where I bought all my stuff. http://****************.com/smile/emthup.gif
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (Disco_Potato)

is cf any harder to work with that fiber glass? i have a lot of exp with glass and was thinking about doing something like this thanks, looks amazing!
 

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Re: Carbon fiber is cool My intercooler will be just as SWEET.. (passatvr6er)

CF is no harder to work on than glass. CF twill is nicer in corners than fiberglass cloth. You usually use epoxy (like West System) rather than polyester resin.
I think if you're gonna lay up intake parts over foam you will need to think of a way to close the pores of the foam (like wax that the gas will eat too, but the epoxy won't--that won't eat the foam either!) or else the inside may not be as smooth as you'd like. I've never tried it though.
That's the great thing about this method--that the mold is on the inside where the smoothness needs to be.
Cheers.
 

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u got im .. very nice .. anyone know where to get cr sheets .. or know what buissnessed to look up in the yellow pages for local supplyers .. should composit matierals stores have this .. thanks
 

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Re: (jazzpur)

One thing that would make life allot easier when making parts like these is carbon fiber sleeving. That way you'll have zero seams, smooth ID/OD, uniform thickness, and you save yourself allot of time. I believe that most CF intakes are made with it. I've never used the larger dia. stuff but I had great results with the smaller stuff.
 

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Re: (turbo 20v)

Quote, originally posted by turbo 20v »
anyone know where to get cr sheets .. or know what buissnessed to look up in the yellow pages for local supplyers .. should composit matierals stores have this .. thanks

http://www.selectproducts.com/frames.html this is one of the best places for any kind of fabrics ie glass, carbon, and kevlar... also how much cf was needed for an intake that size?


Modified by passatvr6er at 5:57 PM 2-14-2004
 

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Re: (1Spike)

Quote, originally posted by 1Spike »
One thing that would make life allot easier when making parts like these is carbon fiber sleeving. That way you'll have zero seams, smooth ID/OD, uniform thickness, and you save yourself allot of time. I believe that most CF intakes are made with it. I've never used the larger dia. stuff but I had great results with the smaller stuff.

enliten us
. is this using some type of mold ..
 

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Re: (turbo 20v)

im pretty sure hes talking about using carbon fiber sleeving... or rather premade tubes of carbon fiber kind of thing, like buying hose and then shaping it and epoxying its shape.. i think
 

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Re: (passatvr6er)

You have to use the sleeving over a plug. The plug (mold) can be whatever you want, aluminum, steel, foam, plastic, and so on. For example to keep things cheap, and still look hella cool. You could make all you intercooler piping from aluminized mild steel, smooth out all the welds and imperfection and the then slide the braided CF over the tubing pull it tight and epoxy it. You could also make your plug out of foam and melt it out after the epoxy has set. But at 30-40 bucks a foot CF only piping would be big $$.
http://www.deltronix.com/public/acp/acp-bcs.htm
 

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Discussion Starter · #19 ·
Re: (1Spike)

Check out http://www.fiberlay.com You can get 10.5oz twill weave 50"wide 36" long for 35 bucks. You can also search on Ebay and find it cheap.
As for intercooler tubing you could make the mold from cardboard and paper mache then soak it out in water. Just put some mold release on it.
Not all that hard. But I went with polished 2.5" aluminum for my tubbing.
 
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