custom intake for 3.4dohc turbo

Kohburn · Post by **Kohburn** » Mon Oct 31, 2005 3:51 pm

Oversteer wrote:Can you give me the contact info you have?

just as soon as i test it out with the fiber - don't want to give out bad information

Oversteer · Post by **Oversteer** » Mon Oct 31, 2005 3:57 pm

Cool. Thanks buddy

Aaron · Post by **Aaron** » Mon Oct 31, 2005 6:32 pm

donk_316 wrote:
Kohburn wrote:
Oversteer wrote:Are you just using the resin? No fibre material?
yeah I'm using some fiberglass cloth in mine but the resin itself has a 10,000psi rating

when its all done i may make a ceramic mold of it and cast aluminum copies
Do it. I wanna run one.

I'd buy one too, and would be willing to spend nearly $500 for it. Any more than that and I'll shy away becuase I could do it myself for around $100.

donk_316 · Post by **donk_316** » Mon Oct 31, 2005 6:49 pm

aaron wrote: I'd buy one too, and would be willing to spend nearly $500 for it. Any more than that and I'll shy away becuase I could do it myself for around $100.

Aaron...here is a little advice from me to you regarding negotation. Never ever say what you just did.

Kids these days...Think they know everything.

whipped · Post by **whipped** » Mon Oct 31, 2005 6:56 pm

Getting it cast in aluminum might be your best bet. I think you're going to have separation problems with the aluminum and epoxy.

S8n · Post by **S8n** » Mon Oct 31, 2005 7:24 pm

whipped wrote:Getting it cast in aluminum might be your best bet. I think you're going to have separation problems with the aluminum and epoxy.

Aluminum heat-soakes too easily though. It'll be worth some trial and error to get the aluminum and epoxy working.

Aaron · Post by **Aaron** » Mon Oct 31, 2005 7:41 pm

donk_316 wrote:
aaron wrote: I'd buy one too, and would be willing to spend nearly $500 for it. Any more than that and I'll shy away becuase I could do it myself for around $100.
aaron...here is a little advice from me to you regarding negotation. Never ever say what you just did.

Kids these days...Think they know everything.

Why, becuase I offered him a price I'd be willing to pay?

This wouldn't be for me anyways, it'd be for my friend who is planning a 3.4 Fiero as well.

donk_316 · Post by **donk_316** » Mon Oct 31, 2005 7:48 pm

aaron wrote: Why, becuase I offered him a price I'd be willing to pay?

Exactly. Negotiation is an art form. But whatever.

Aaron · Post by **Aaron** » Mon Oct 31, 2005 7:59 pm

donk_316 wrote:
aaron wrote: Why, becuase I offered him a price I'd be willing to pay?
Exactly. Negotiation is an art form. But whatever.

I don't need to negotiate. If I want the intake, and I trust his skills, and I have the money, I will gladly pay what I think it is worth, which IMO is "up to" $500.

donk_316 · Post by **donk_316** » Mon Oct 31, 2005 8:23 pm

aaron wrote: I don't need to negotiate. If I want the intake, and I trust his skills, and I have the money, I will gladly pay what I think it is worth, which IMO is "up to" $500.

Nevermind. Its cool.

Kohburn · Post by **Kohburn** » Tue Nov 01, 2005 7:42 am

whipped wrote:Getting it cast in aluminum might be your best bet. I think you're going to have separation problems with the aluminum and epoxy.

the epoxy i'm currently using maintains a bond strength of 1000psi at 450*F so it shouldn't seperate without a nitrous backfire

Kohburn · Post by **Kohburn** » Tue Nov 01, 2005 7:49 am

aaron wrote: I'd buy one too, and would be willing to spend nearly $500 for it. Any more than that and I'll shy away becuase I could do it myself for around $100.

there are two options really - cast aluminum and cast plastic

the materials for cast plastic are more expensive
but the materials to make the mold for cast aluminum and the equipment to melt the aluminum are more expensive

so really its all about quantity as to which is more feasable

but either way should be able to keep the price down to be a bit more reasonable.

---- may as well toss in an update

used some spray foam again last night to bond the green foam peices together and to fill in that groove on the top and build up a little more..
I'm going to hold off on pics untill its finished and ready for epoxy covering - after that no more pics till its completed

whipped · Post by **whipped** » Tue Nov 01, 2005 10:39 am

Kohburn wrote:
whipped wrote:Getting it cast in aluminum might be your best bet. I think you're going to have separation problems with the aluminum and epoxy.
the epoxy i'm currently using maintains a bond strength of 1000psi at 450*F so it shouldn't seperate without a nitrous backfire

well I'll see your 1000psi, and raise you 10,000psi for thermal expansion :la:

F/A = E*d/L

d = c*T*L
so
F = E*c*T*A
E is young's modulus
c is coefficient of thermal expansion
T is rise in temperature
A is cross sectional area

Kohburn · Post by **Kohburn** » Tue Nov 01, 2005 10:53 am

whipped wrote:
Kohburn wrote:
whipped wrote:Getting it cast in aluminum might be your best bet. I think you're going to have separation problems with the aluminum and epoxy.
the epoxy i'm currently using maintains a bond strength of 1000psi at 450*F so it shouldn't seperate without a nitrous backfire
well I'll see your 1000psi, and raise you 10,000psi for thermal expansion :la:

F/A = E*d/L

d = c*T*L
so
F = E*c*T*A
E is young's modulus
c is coefficient of thermal expansion
T is rise in temperature
A is cross sectional area

so which one do you think is going to expand more.. solid aluminum of the 6061-T6 variety, or aluminum filled epoxy with a 10,000psi tensile strength (i'd have to check its spec sheet to see if they privided anything for thermal expansion, but i doubt they did)

and do you think that the expansion will exceed the epoxies elasticity? I don't - granted some epoxies are very brittle, most I work with are not

I also higly doubt the intake will ever even see 200* let alone 500* that the epoxy is good to

whipped · Post by **whipped** » Tue Nov 01, 2005 12:45 pm

Kohburn wrote: so which one do you think is going to expand more.. solid aluminum of the 6061-T6 variety, or aluminum filled epoxy with a 10,000psi tensile strength (i'd have to check its spec sheet to see if they privided anything for thermal expansion, but i doubt they did)

and do you think that the expansion will exceed the epoxies elasticity? I don't - granted some epoxies are very brittle, most I work with are not

I also higly doubt the intake will ever even see 200* let alone 500* that the epoxy is good to

The aluminum, easily. Plan on cycling the intake from 30 degrees to engine overheating (250+) temps.

Kohburn · Post by **Kohburn** » Tue Nov 01, 2005 1:06 pm

whipped wrote: The aluminum, easily. Plan on cycling the intake from 30 degrees to engine overheating (250+) temps.

the intake never gets that hot - it has ambient air flowing through it non stop cooling it

granted under a lot of boost it'll see higher temps but its still doubtful it'll ever see temps over 200

p8ntman442 · Post by **p8ntman442** » Tue Nov 01, 2005 1:56 pm

make a spacer that is made out of ultra high molecular weight plastic. That will keep the engine heat from transfering into the intake as much. (martha stewart cutting board from kmart is good for this).

Kohburn · Post by **Kohburn** » Tue Nov 01, 2005 2:02 pm

its not necessary

Aaron · Post by **Aaron** » Tue Nov 01, 2005 2:22 pm

Kohburn wrote:
aaron wrote: I'd buy one too, and would be willing to spend nearly $500 for it. Any more than that and I'll shy away becuase I could do it myself for around $100.
there are two options really - cast aluminum and cast plastic

the materials for cast plastic are more expensive
but the materials to make the mold for cast aluminum and the equipment to melt the aluminum are more expensive

so really its all about quantity as to which is more feasable

but either way should be able to keep the price down to be a bit more reasonable.

Aluminum or plastic I could honestly care less which. And remember also that you could have quite a few of the W-body 3.4 people interested as well, even though it is a short runner intake. I say go for it.

Kohburn · Post by **Kohburn** » Wed Nov 02, 2005 6:27 pm

ok couldn't help myself - here is a pic of the foam covered in silicon