Precision Auto Engineering


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Hanaldo
Hanaldo
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Hey all,

I am doing a lot of work for the race team Precision Auto Engineering, so I decided I will put all the work I do for them into one thread rather than making a hundred threads for each different car that I do. 

So first off, the GTO Monaro. Been doing a lot of work for this car for about 4 months now, it was a pretty major project. Basically I needed to make the airbox and intake plenums for the car, as they had a custom LS7 inlet manifold made by Harrop but Harrop couldn't supply any of the support gear. So here is what I came up with:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10620678_548506048614149_2312705000742828305_n.jpg?oh=e00a06d5d86f05fe69ef9b11f5687adf&oe=5546F975&__gda__=1426131779_9ad512c8cbadcc9bca6ae71aeefddce6


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10474253_548515395279881_903836919387585914_n.jpg?oh=c5218e3a4df565dad5afc5ade38f9d1e&oe=5506423C&__gda__=1425652085_d43310648705e5ff93935d8c04e49030




The grooves through the middle are for the panel filters to slide into and the 'tabs' are to lock them in place. The 'PAE' lettering was an extra little touch that I threw in, although in hindsight I should have put my business logo on it somewhere too!

So from there I made the moulds:

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10352951_560468477417906_5660083238514328772_n.jpg?oh=b30dfaa0b5d4c6d00172133aa4a8dac6&oe=55387100&__gda__=1430049208_36307e8494706da042831c1c08a6e0e1


https://scontent-b-sjc.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10410259_560468540751233_75149730554154560_n.jpg?oh=cec9eec9e88173ba07c0f4b92dd30184&oe=5501A828




Unfortunately I don't have any good photos of the plenum moulds, but they were quite complex 4 part moulds which you can sort of see in the background in these photos:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10420002_564940136970740_5776856814339873791_n.jpg?oh=ad3bebf4f743eae9313a944a73492ba3&oe=553841AB


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10730770_564940153637405_7515214671343809043_n.jpg?oh=c51b41a9de7248e8849c5402d63a306a&oe=550B8DFF&__gda__=1426411847_2db1f2f6580d0aba512ffc0a7ec7a930


And the second one:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/p296x100/10801768_569339419864145_1007048780783432528_n.jpg?oh=4ce1baa51aff4fdec44d8ef5fda3f5a6&oe=5538F6D3


https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10377533_569339439864143_2531029508864573797_n.jpg?oh=34c1ebc06ff0953212efec1907055205&oe=54FEF088&__gda__=1429744432_c4feaceb1bb5d97b35f73ab204960303


Plenums trimmed and polished up:

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10177926_565871240210963_3280382397881118313_n.jpg?oh=cb3ad6843dd81379e4a363f6a45affc2&oe=55341088&__gda__=1426095842_9dc907764702a69209213e72c4264456




Then the airbox infused:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/q83/p296x100/10733960_575058005958953_8281474937702305077_n.jpg?oh=935ba304a292e1f576aae3a3d93ed9d9&oe=5508C5D0


https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/1656139_575058029292284_5019364289971787450_n.jpg?oh=722f4843b636a264503665a7116b75fb&oe=550BBAFB&__gda__=1426711979_435dd6f48138221c1950a5a940bd9b3e


Bonded together:

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10882280_10152428929302541_3455938312912656286_n.jpg?oh=ac0bdb440406b8080321e5532729f612&oe=54FFD140&__gda__=1425971373_cc10be1232bad7e2cb403c36b5f0c465


https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10704084_10152428929092541_2522541129817934050_n.jpg?oh=f757ef1b76c66fab7f88707d54986687&oe=54FEA375&__gda__=1430533219_26fbb20defaf9f3d33346d12dad32b72




Everything dummy fitted:

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10805669_575058225958931_7771916781417976408_n.jpg?oh=5a4da713846b461857f7f55558761c7c&oe=5509F92D&__gda__=1426004117_aa35318285fc00c668e879b308e1b8a1




Airbox sprayed with Duratec Sunshield:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/1782158_575058425958911_5923607789755957796_n.jpg?oh=c3da71a427e8ec51601ebdb4779bb5a7&oe=5509AE44&__gda__=1426735418_9dfbe8c03ab0aa8469b5a6c40edbd57a




Then flatted back and polished:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/1458483_580008655463888_7226678496232552068_n.jpg?oh=c745c4a79aa5a10386a68d0a6178c930&oe=5541CB72


Also made those carbon blanking panels to cover the empty spaces.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10641199_580008622130558_2583019143134961029_n.jpg?oh=16d27e82ff690a6e8ea3fdaa93e7289b&oe=5546BF08


Finished off the engine bay with this carbon fibre fuse box cover

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10846309_588961494568604_1140743403344807652_n.jpg?oh=4491e9d1e76678f728a2a0ce0351b51a&oe=5541B322&__gda__=1430628350_9b2bf5307c8ea2dde7eec2dee8574530




https://scontent-b-sjc.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10849799_588961507901936_9134674367664326584_n.jpg?oh=292b0df3c4f8ca15b272875f3c2e8b59&oe=55020F65


https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10382976_588961531235267_8346240599711412113_n.jpg?oh=a0c7a9d32ad65369ba650cff9a029bc7&oe=5506AF54&__gda__=1429891170_a0caabaabbbe8225ea5161178339c628


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10500582_588961611235259_4846288595464528921_n.jpg?oh=2cd32e14d856d535032eb52e48cc0039&oe=5504A12A&__gda__=1430442395_c40d9de5781571fd5d09d4f2ccefd0f7




Not a bad looking way to make a naturally aspirated 1000rwhp! w00t

Hanaldo
Hanaldo
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Some of you may remember this Motec electronic dash mount that I made awhile back:

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10563046_529450900519664_7497071240877275634_n.jpg?oh=a2fc06b6641e71b983dc2e017e6838dd&oe=55360636&__gda__=1430189447_af2c432ba5466f6f27b89bad0b0b7368


However we since decided that this had design issues, and could be done better. So I made version 2, featuring recessed bolts, a more compact design, and a v-weave finish:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/1016287_10152428945737541_877263249558115138_n.jpg?oh=b11dac87118bbc094e6fed2299db7db2&oe=5545CAC5


https://scontent-b-sjc.xx.fbcdn.net/hphotos-xfp1/v/t1.0-9/10254978_10152428945867541_7363111239173619024_n.jpg?oh=b047ced1a0e836a975f303bd71029eb3&oe=553CD972


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10294315_588962111235209_3100473401351953205_n.jpg?oh=59b9737e2ce99ab1d70515297c997089&oe=55032EAF&__gda__=1430119877_9cb1b9685c1ec5e663cb42242e31af5d


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10847918_588962131235207_1484878043468058484_n.jpg?oh=5661060163a00e56aaf1a31c48d31bbb&oe=55051087&__gda__=1426335551_077ebf6735908693e8a10ef37c950a1c


https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10849740_588962147901872_5507839997936921698_n.jpg?oh=5cb8b67c68baf06280a076cabe2f33db&oe=55010CC1&__gda__=1426801008_bc15bba94aed85bb7c57e41b2bc42407


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10431526_588962167901870_5367463344468261874_n.jpg?oh=e8d266778e46317cc3ce145da44b9975&oe=54FE873A&__gda__=1429978803_d8c0b20ea255856d5122932a4766e01b




Hanaldo
Hanaldo
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And then this is what I am working on at the moment; a bit of arts and craft to fit a NASCAR motor into an EL Falcon:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10846445_588961271235293_4082286252609252651_n.jpg?oh=53f02cc795fbc2b27f8da48f6e130f3b&oe=5547F1E7


https://scontent-a-sjc.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/1907338_588961284568625_7935685868143544078_n.jpg?oh=5bd69e2b09b88ef7f4d2f27cbac37321&oe=550947B9


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10868111_588961324568621_6598292516886146603_n.jpg?oh=dc0cbb38726d6f94763cb965750cbbbd&oe=554759C0&__gda__=1430572664_9b4fb479accd94b7273506b2f19393e5


https://scontent-a-sjc.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10405672_588961354568618_8975114556025023802_n.jpg?oh=302ff91cae2f015ced57850f2c4c5b02&oe=5546A3BE




I'll update with photos as I progress.
Brian2fast
Brian2fast
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Hi Hanaldo

This is what we want! Lots of photographs of patterns, moulds and parts. Cool.  Smile

What are the letters 'PAE' made from on the patteren?

The plenum looks to be one carbon part. Was that tricky to layup the fabric around the tubular area where the silicon connector clamps to?

Any idea how many hours you spent on any of them?
The finish looks great.


Craig
TomDesign
TomDesign
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ye already sended him PMBigGrin
Hanaldo
Hanaldo
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Thanks guys Smile 

Tom, I will reply to your pm as soon as I can Smile 

Brian, you're correct, the plenum was infused in one piece. I'll try to get some photos of the mould for you. Basically they were 4 part moulds, and I laid each of them up individually and trimmed the carbon flush with the split lines prior to bolting the pieces together. Then laid strips of carbon over the joins and then the usual consumables. It's tricky to do but the results make it worth it. 

The 'PAE' lettering was just made from balsa wood,sealed with epoxy and microballoons, then painted over. The picture doesn't show it but I put a radius on the edges of the letters using filleting wax before making the mould. 

You don't even want to know the hours in these. Those plugs for the plenum and airbox alone are worth ~10k in labour. The moulds are about 2.5k, and the final carbon parts are about 900 each. 
Matthieu Libeert
Matthieu Libeert
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good job! love to see projects like these Smile

Matthieu Libeert
Founder MAT2 Composites X Sports
website:
www.mat2composites.com




scottracing
scottracing
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good work, i enjoy seeing the tooling nearly as much as the final parts!
TomDesign
TomDesign
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and looking forward on PM BigGrin
Hanaldo
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Realised I never updated this after I finished! Went to Europe for 2 months the day after completing it, so it slipped my mind... I'll just upload some photos for anyone that's interested:

https://scontent-sin.xx.fbcdn.net/hphotos-xpt1/v/t1.0-9/10418897_590957271035693_1925357298466576436_n.jpg?oh=dcd0e996ebee9578b0f321e6c04cfc19&oe=55979B66


https://scontent-sin.xx.fbcdn.net/hphotos-xap1/v/t1.0-9/10868280_590957394369014_5472048802108177025_n.jpg?oh=7da44fcd3585e10a1d20d0c2a0b4766d&oe=55B51FD3


https://scontent-sin.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/1505387_590958054368948_6896080542754134800_n.jpg?oh=8d5482a259ab11f9bc86fc3358f91a94&oe=55AB2FA7


https://scontent-sin.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10422308_590958374368916_6323652416869013641_n.jpg?oh=327cb04d50f770f60f6b7e539dbc8695&oe=559F096E


https://scontent-sin.xx.fbcdn.net/hphotos-xpf1/v/t1.0-9/10685503_597719437026143_807894413404061005_n.jpg?oh=654d39e0b63e261b92ea7dcb43f113d7&oe=55A59E7D


https://scontent-sin.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10690260_600966546701432_8033779186461082517_n.jpg?oh=8065998f0a5e5494613b4f20d7d1bba5&oe=55B45C24


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10426770_600966506701436_7323755205627735996_n.jpg?oh=b0b092473f46bbea1698dc36d0d876af&oe=55A05504&__gda__=1438161262_cc53279bc1b12d4303350d13e6e60df8


https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/983840_600966530034767_2185209147346092769_n.jpg?oh=0ccf9e4afdf80be874cfa03e2256a13d&oe=55AECC2A&__gda__=1436275398_18b39fcb20f16dabbb3aa0de3bb258bc


https://scontent-sin.xx.fbcdn.net/hphotos-xft1/v/t1.0-9/10430421_600966573368096_4470234312946299297_n.jpg?oh=ba0be367970699094861044628227cd9&oe=55AD2B34


https://scontent-sin.xx.fbcdn.net/hphotos-xtp1/v/t1.0-9/q81/s851x315/10481574_606043049527115_4559299743885372261_n.jpg?oh=f2a3be915a07de40e1341ce9000d3625&oe=55BB0C1B


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10917449_606043116193775_6881049938843409303_n.jpg?oh=769f9a4074bd1138beb177299ba0dd46&oe=55977144&__gda__=1437974268_ade417032b886227d14f8e87cb2ea712


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/1511121_608355369295883_2107417876192301995_n.jpg?oh=61f4e1e9c21ba918dbd843cb1456f053&oe=559F9CB5&__gda__=1438289381_141e7b4093469c1c643bef0301a7a54c


https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/s851x315/10686606_608355845962502_9048555638769806311_n.jpg?oh=62fc194b136cfd6396aa422c971618f0&oe=5598A1AB&__gda__=1438150221_b0406cbe5d8a4b208a7d543c32ca3f21


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10931471_608355859295834_6672948657815765341_n.jpg?oh=ca4697cf7265b435b4b3d45544d99cd4&oe=55A2E582&__gda__=1437013555_6045e0f01b3144f9a9bcc8a7f6acd7f4


https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10003899_608355889295831_143496402304856567_n.jpg?oh=77639837ef27ba1823fcc001aef30478&oe=55B34960&__gda__=1438012321_7e64b55908635e4577c8ff9004a9e8b9






Final product weighed 6.0kg, the original steel bonnet weighed in at 16.3kg, so managed to save 10.3kg and grow a bulge Wink
GO

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