DIY Carbon Fiber Intake Manifold - Part 4: Finishing the Job
HTML-код
- Опубликовано: 8 сен 2024
- The FINAL episode in making the carbon fiber intake. We get the parts all epoxied together and checked on the car. It's a lot of work, but the results speak for themselves.
throttle-stop-...
"Make the noise!" oh wait! wrong channel :)
Pretty much!
@@ThrottleStopGarage the only RUclips build series thats taken longer than yours 😋
Keep up the great work. By far the best information on laying custom carbon fiber work.
@@ChuckThree I know - I think they have a 3 year head start though.
Awesome comment 😂🤣 sad that I knew what you meant without even having to think 😂
that's a bad obsession... ahahha
Nothing lost by the wait, it's such a well thought out build, it's easy to follow and compelling to watch.
Thanks Scott.
Awesome 👌
This has to be one of the most beautiful intakes I have EVER seen. Magnificent work.
Wow, thank you!
@@ThrottleStopGarage I honestly would pay for a product of this caliber if you made them for my car. good stuff and love all that you have done. top-notch. if you have an instagram post it up I would love to follow and share you beautiful build
@@Vexman2200 Thanks - much appreciated. You can follow me on instagram at throttlestopgarage
Absolutely one of my top channels! The quality of work you do and the amount of teaching you do on each and every video is unparalleled even by some of the highest budget channels. Thanks for always keeping me wanting to come back for more!
Wow, thank you! I just keep trying to pass along what I've learned.
Your attention to detail and carefully executed build processes that are the best part of this channel. Also not trying to peddle tools and products is a bonus. Your a true "sharer of knowledge" - I do admire that about you.
Look forward to your build in progress as usual and always joy to watch and learn.
I appreciate that!
It came out amazing! One of the most professional diy builds ever! As a builder and ex racer I do admire and respect your attention to detail. And the video editing is in the same level with everything else.
Thanks - that's much appreciated. I was laughing at the segments where you can see the GoPro in the shot...it's hard to work with a camera in the way all the time!
That intake manifold is a work of art!
Thanks - it's back in the house...safe from the garage.
That is a stunning result. Hopefully you'll be able to tear down the engine and get all of the exterior repainted for a similarly clean aesthetic.
That's the idea. I'm a sucker for a detail and love keeping things clean.
That piece is automotive art. Just wow.
Thanks Brad.
Amazing result - 👍👍😎👍👍. Hang in there..... we’ll be here when you’re ready.
Thanks 👍
You really give DIY'ers hope. This build is particularity fascinating cause I have a 5cyl I think I want to rinker with myself and there's not a aftermarket for it. Bunch of fab work necessary
Thanks - it's a simple vision that got a little out of hand!
@@ThrottleStopGarage hahahaha those are the best kind! You've got me wanting to put 20k into a 5k truck
That's a piece of art of I ever seen one! Really beautiful!
Thanks Peter.
What an astonishing master piece!!!!!! Congrats from México
Thanks!
9:09 wait for it! Loved that! Anyway great stuff! Bravo! you really got soul in it
Glad you enjoyed it!
Nice job. That was a lot of work, but the final product is amazing!
Thanks. I can't wait to get it running ro see how it works.
I found in some applications polyester pigment coloring additive can cause sever hardening problems 80° temperature is a big help .
Interesting. I only used just enough to turn colour - it hardened fine (or it seemed to) - what sort of problem did you encounter?
Well done! Love the result 👍🏾
Thank you! Cheers!
Love your videos totally worth the wait! Especially the intake mani series has been super interesting. Thank you for all the insights you share.
Glad you like them and that you're finding them useful.
Stnning work!! really enjoyed this 4 part series
Thanks - much appreciated.
Turned out awesome Throttle!
Thanks again!
Glad to see you back!
Thanks Peter - should be able to post more regularly for the next few months anyway. Trying to give it a bit of a push coming up.
Outstanding! You should be extremely proud of your effort there, intakes don't come any better looking than that.
I appreciate that! I just hope it works well.
Thanks for sharing. Appreciate all the hours of work you do that we don’t see.👍
Thanks - much appreciated.
That manifold looks absolutly AMAZING great work!
Thank you!
Turned out great! Keep up the work
Thank you!
Super work Budy 👍👌 i can,t wait for the next video 🤗😎 All the best from Switzerland Daniel
Thank you! Cheers!
That's looking perfect.
Good to see you again and really looking forward to seeing how you go about building the exhaust manifold👍
Thanks Gareth - I've got the collector cut and should be welding it this week. 321 stainless. Fingers crossed.
@@ThrottleStopGarage can't wait to see it👍
Awesomeness as usual. Love your work. Cant wait for the manifold build👍
Trying to get to the collector. It's coming.
Very impressive! Brilliant work
Thank you! Cheers!
Hell yeah been excited to see this for a while!
Thanks
Worth the wait. Will be waiting patiently for the turbo manifold video!
Coming soon!
happy to see you back at it. that is a very nice looking part you made.
Thank you! Cheers!
This intake has sure set the bar for the rest of the car's finish. This car will take 50 years to build if you make the rest of it this perfect.
It will take the time it takes.
Turned out awesome!
Thank you! Cheers!
Hey Craig, when you first moved the intake runners to the bench for glue up I noticed that the injector ports where on the bottom and I said "Oh hell no"! But of course that Canadian meticulitus caught it with plenty of time to spare. "Remember, the women don't need to find you handsome, they just need to find you handy!" my fav Red Green quote.
LOL - Alan - That's what was running in my head the entire time..."Don't put the plenum on backwards!" I was reasonably panicked the entire time. Oh, I haven't forgot about the pics I have to send. I'll see if I can get to that today.
It came out awesome! Looking forward to seeing your turbo manifold work!
You and me both!
@Throttle Stop Garage absolutely love the intake manifold. Cannot wait to hear her run. I really liked the way you designed the intake manifold plenum base. If you are open to sharing, Id love a copy of the drawing you designed to use on my own build!
This plenum part only works if you are using the 960 intake flange. There is a slight offset of one of the holes. So unless you have that part, the model won't really be of any use.
Always love the precision.
Thanks!
Epoxies are also used in the aerospace industry . Be surprised how much parts are actually put together with epoxy on a rocket/spacecraft.
Thanks good vid.👍
Great point!
Wow that looks amazing! Any other parts on the car getting the carbon fiber treatment?
So far I've made a trunk, hood, fenders, doors...and this intake.
@@ThrottleStopGarage I think I need to go back in time and watch more of your stuff. This car will put most Swedish builds to shame. It really makes me want to do a similar style intake for my 242.
@@SeanHodgins I've got a 242 and a 245...I've also kept the mold as the intake on the 242 is just the stock turbo manifold which is a mess.
beautiful. always look forward to your updates
Thank you! Cheers!
I got the Bad Obsession reference :)
LOL - Love their channel.
Always great work!
Thanks again!
A second thumbs up for cleaning your bench :P
Thanks! It was a lot of work - two car loads went to metal recycling.
@@ThrottleStopGarage :O holy crap
dude, tumb up, very nice
Thanks!
It looks awesome!😲
Thanks - I'm sure happy with how it all turned out.
Came out looking really really good. Now you will need to match the rocker cover colour to the runner color.
Interested to see what is going to happen on the hot side.
Thanks! The engine covers won't be painted...the engine will be painted. Working on the collector for the turbo right now.
Carbon fiber composite has a very low thermal coefficient of expansion, aluminum has a fairly high thermal expansion. Hopefully your bond joint is not overstressed due to the min and max temperature range that the manifold will see. Your intake manifold length is maybe 18" long? I enjoy the work you are doing.
I hope not - we'll see when it's all together.
Great finished part!
Thanks
Spectacular
Thanks
Great job. Congratulations!!
Thank you!
WOW, F1 quality Craig. Ian in G.B
Thanks 👍
Great looking part! Just curious if any worry/consideration has been put into Galvanic corrosion between the carbon and aluminum especially since this is the engine intake?
Missed the on-screen note about testing them the first time🤦♂️ either way any tips or ideas on how to avoid that in a part like this?
Use the correct epoxy was a big part of the step. If not, you can isolate the parts using fibreglass veil.
That look really nice 👍
Thank you! Cheers!
Looks great.
Thanks!
Looks great
Thanks!
Love the content. Keep it rolling, brother!
Appreciate it!
Just had a crazy idea about weight reduction of the engine bay, which led me here. You’ve already done what I had in my mind! AWESOME! Now, how does it perform?
I don't know yet. Still building the car.
Nice one, looks amazing 👍
Thanks.
It should have been easier to lay up the carbon over smaller 3D printed wax core or a plastic core made to separate. All done in one go. More external polishing needed but far less risk of a useless moulding.
I see what your saying - but I've never done it that way before. I'm not sure how it would all work out with such a complex part. I was also interested in having a nice outside carbon weave on the finished part.
Thanks tat really helped
Glad it helped
Ave. Keep your stick on the vice.
LOL
Mate, you should be really proud of yourself, that's a beautiful piece of work, is it possible to contact you for some advice? I have a Jaguar XF SV8 4.2 Supercharged and I want to make a custom intake for it "While the missus is on holiday"
Sure - DM on Instagram. Happy to help.
Loved this build along! Did you end fixing your furnace blower wheel and motor? Lol
I did - the inducer motor was toast and there was a problem with one of the sensors. It's so quiet now I barely know it's on!
Yay . been waiting for this
Thanks.
really enjoy your approach and videos, great result. One question and (not a criticism) was why make the fitting to the manifold permanent ?
Do you mean the carbon plenum to the aluminum? I considered having it removable, but that was more complex and I wasn't seeing the benefit. If it fails, we'll have to go back to the drawing board.
I saw what you did there; "Keep your stick on the ice". After hearing, that and not being from Canuckistan, I gather that what AvE says is a play on words. Am I right?
Yes - AVE stole it from The Red Green Show...and Steve Smith stole it from every hockey coach ever. Every kid that ever played has heard it from a coach at some point.
Looks fantastic. Any plans for matching carbon fibre timing belt covers and ignition coil cover?
Not sure yet - I have an "R" engine and will probably use the blue covers. I really should do an update video to catch everyone up on what's going on.
@@ThrottleStopGarage I think an update video would be great. I joined the series as you started the composites work so not fully in the loop.
Got to say I love what you've achieved with the composites. Shows what patience and determination can do even without all the experience.
You didn't mention it but I am very curious about the final weight of the intake. Looks really light when you're handling it.
I've never put it on a scale Aaron. My guess is it's around 3 kg without the throttle body. The base plenum part could have been lighter.
damn nice job!
Thank you.
So you are so busy that you made a 15 minute video of you applying glue.. wow.. great... LOL.. JK.. always enjoy your content. Keep it up. One day I am going to do what you are doing to an old Toyota.
Yes - and it took me three months to get it done.
amazing work. What volvo engine are u using?
5 cylinder - 2.3 L.
Can you hook up an airline to it block the ports off see if it can handle boost ?
I sure could - but I'll wait for that until I've got the engine built.
12:03 But you let it sit for the 72 hours *with* the masking tape?
No, I pulled the tape as soon as the epoxy was applied and I'd cleaned the area with acetone. Then I let it sit.
Great video!
I’m wondering what type of clear coat did you use? Is it heat resistant?
Thanks.
It's a UTech 4.0 high solids clear. It's as heat resistant as it needs to be for this job.
Hello! Great video and channel! I did like to know if is there a way to calculate the right number of carbon foils to ensure a right strenght according to a definite weight of charge in axial direction. Any tools, excel page or something like this that could return the right value? Thank you!
There are a few calculators on retailer websites that will tell you finished thickness (those I've found to be accurate if you get the epoxy ratio optimized). Strength of the finished product is complex - it's not just filament orientation and layup, but it's also quantity of resin (less is more) and general quality of the materials. So I'm not sure there is anything that can make this "simple". I used to look - I did a lot of research. My advice is to at least match the metal panel you're replacing (if that's what you're doing) that would ensure that it was over done. The rest would entail calculating. For the plenum, I just did some simple calculations and set the thickness based on that. I really don't know if it will work - but it should.
@@ThrottleStopGarage Thanks for your help! I'll try to find more on speicific study or analysis :)
Nice job! Is the car running yet? Curious how the manifold performed.
Nope - not even close I'm afraid.
But is that epoxy fuel, heat and expansion proof? For panels I could imagine it working
Yes - of course. It's heat resistant and resist all automotive fluids. They use to to adhere jet engine covers. I'm not understanding your question very well. If you have some specific information, I'm all ears. Otherwise, I've thoroughly researched the product to the point that I can.
Why not clear and sand the inside of the plenum where the smoothness actually does something.
Shape not shine is the rule for intakes as far as I know.
Hello, your work is amazing!! Do you take custom jobs?
Thanks but nope - I've got too much to do on this car.
Now pressure test it, to see if it can handle 80psi of boost.
All in good time - I'm not worried about the absolute pressure, but the transient spikes and pressure cycling.
How has the intake held up so far? Loved this series/project
It will be a few years before it gets run unfortunately. Sorry for being so slow - real job gets in the way most of the time.
@@ThrottleStopGarage heyy i totally understand!!! No worries, ive been thinking about creating a intake myself and following your step's, same materials, except i will use a high-impact clear coat in the end. Are you on facebook?
@@davidsean7043 On FB and Instagram.
Hey Buddy! Great work as always, that Intake Manifold looks sick! How much Boost are you gonna run on the Amazon when its done? (and how much Pressure you think the Intake can hold before failing/splitting/exploding)
Around 2 Bar is what I'm targeting. I think the risk is in the pressure fluctuation not in the pressure itself. It's 2 mm thick - so if I blow it up, you can bet I'll be smiling.
2 Bar beyond atmospheric? Sound like fun even if it splitt's or it throws a rod out the block :-) stay save and keep on the good work!
I've heard you shouldn't bond carbon to aluminum directly. It will corrode since carbon is conductive. Maybe something to consider when you spent so much time on the parts.
It's done all the time - have a look at the front wing on a F1 car - metal bonded to carbon provides the adjustment and support. Airplanes are put together using this epoxy. I research everything extensively - there are elements in this epoxy that keep the parts from "touching".
@@ThrottleStopGarage hey, you're the expert here :) But I was under the impression that they had an intermediate layer of glass fiber. The comparison to F1 is a bit unfair since those are not built to last, which airplanes are though.
Either way, awesome build. As a Swede it makes me a bit proud that you chose a Volvo.
@@johan.mp4 I mentioned it in another comment - but fibreglass veil can be used as an insulator if needed. Loctite would not advise me on the product as I'm just a guy in my garage. There is a Boeing certified method for this product bonding aluminum to carbon fibre. When I first applied it and could verify that it has micro-balloons, I relaxed a bit.
Im retired now I have a chance to work on my project is there a blueprint of your chassie I'm using the E type jag irs and corvette frt end with 12'" rotors . tremic 6 sp with the 7.3 ford. crate engine
What's it going into? I don't have a full blueprint of what I did for the suspension and the chassis legs were bent by Art Morrison Enterprises. In my experience - it would have been A LOT smarter and less expensive to just have AME do the entire clip for me. It sounds expensive at first, but it really isn't when you add it all up.
is there anyone making these parts I'm interested in body parts for my 1967 122 amazon
There is a company in Sweden that makes composite panels for the Amazon.
Это реально круто!
there is something called galvanic corrosion which happens when two different metals touch each other or a metal touches carbon fiber, please read about it if you can, thank you so much
Did you watch the video? I addressed this problem.
@@ThrottleStopGarage i watched it but cants remember how you did it was that epoxy you used to connect two pieces together isolated them ? or it is something else
@@ThrottleStopGarage but whatever you do, mad respect for your achievements and thank you for sharing it with others to learn
@@amirfathirad2965 Yes - the aircraft structural adhesive that was used isolates the parts.
@@ThrottleStopGarage nice idea permission to steal it and use it on my own projects :)
Please tell me that is the intake for one side of a V10. It would be a real travesty if this much work and cost was sunk into a 5 cylinder better used for a turnip fertilizing machine ;)
Turnip fertilizer is my favourite!
@@ThrottleStopGarage cool project. Learning lots of stuff from these videos.
Do you do custom carbon fiber work
Nope - sorry for the late reply.
Did it sit for months to cure or because you had other things going on? 😂
COVID has set this project back over a year because my day job has been and continues to be nuts.
No pressure testing?
Later - for sure.
Im not familiar with them you have address
www.acm.se/en/category/amazon-2
rpglasfiber.com/?go=pro&hcat=7291350&cat=1758034&ucat=9555502&cucat=1758034
These are the ones I know about.
What clear coat did you use?
It's a Utech 4.0 clear. Any standard urethane clear will work.
Wanna make me one? I’ll do all the sanding!👍🏻
Nope...at the pace I go, if I started making parts I'll never finish.
@@ThrottleStopGarage no problem!
Watching the way you did it really gives me the motivation to try it myself! Now I actually need to get off my butt and do it🤣🤣🤣
❤️💪🏼 the channel
Over spray on everything yuck!
Na, it's not really that bad. The coating of dust on everything soaks it up. No paint booth in my little garage.
Well, I’ve been there. Dust, over spray, more dust, more over spray. Eventually had to cut and polish every horizontal part of my car and other stuff to get it off. All those ‘ah it’s only just this time’ moments add up. Awesome work none the less!!
@@stankinasses No worries - there's nothing in my garage that can't handle a little overspray! When the car is painted, I won't be painting in the same space!
Do you do custom carbon fiber work
Sorry - barely enough time for my own stuff right now.