Talk Composites - The Forum for Advanced Composites

Precision Auto Engineering

http://www.talkcomposites.com/Topic14238.aspx

By Hanaldo - 12/21/2014 4:54:12 AM

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
By Hanaldo - 4/7/2015 7:18:21 AM

Would use more silica and less bubbles as well. Bubbles lower the density of the resin.