4" intake pipe


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Hanaldo
Hanaldo
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Hey all,



Thought I would just post up the latest project I have been working on; can always do with being told how to do it better.



So the project is a 4" intake pipe for my R34 Skyline. I wanted to attempt making something from scratch, and given I only had a 3" intake pipe previously I couldn't use that to make a mould for this one. So I started off by using the centreline of my current intake pipe to make a 3D drawing with the dimensions and cross-sections that I needed. I also added 100mm to the straight section on the end, as I wanted to move the air filter further away from the exhaust manifold:













From there I was able to print out the cross-sections I needed, and transfer them to some 3mm balsa wood:

1978698_10151893592392541_851850552_n.jp


Which allowed me to create the skeleton structure of the part:

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I then needed to in-fill the gaps, so I made some low density polyurethane foam using a 2-part pour in place system. With this being the product. I made 4 of these 'blocks'.

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Then I used this foam to fill in the 'body' of my part:

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Trimmed and sanded down to size, and voila!

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From here, I filled and sealed the part with epoxy resin filled with microballoons:

1625670_10151893592107541_491525122_n.jp

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Then used a stainless steel and fibreglass reinforced body filler to fill in the big gaps:

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Flattened it down: 

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Then used the same filler to cover the whole thing, so I could fill in any low spots in the foam:

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Sanded it down again, then trial fitted it in the car:

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Perfect fitment to the mm!

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wildcard
wildcard
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Yah they aren't cheap. A grand for each rim, but when you have a car that has 800 plus hp on low boost settings and that I plan on doing standing mile events, it is justifiable--barely. Yah at first I couldn't understand why rims were so much money, but the japan companies rigioursly test there products so that they exceed OEM standards. The rears, I have to increase because of the new widebody. I didn't feel safe with getting them back rays cut and widened or rebarrelled. Not with 608+ ft/lb of torque... And the only similar looking rims are Works Meister SP1 and SP3s, and SSR Professors. I decided to go mismatched so I'm buying a Work rim from the gnosis line. Save some money, but still get the new dimensions and offset that I need. The benefit of mismatched is that I can keep wall if the old set and just use then as front rims. I'll have f: 19x9.5 and 19x10; r: 19x11. I hope to be placing that rim order soon--it takes 3 months to get them, so I want to get the ball rolling. 
GO

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