Carbon fiber intake plenum

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Elias_GR	Elias_GR posted 9 Years Ago HOT Topic Details
Group: Forum Members Posts: 11, Visits: 604	Hello everyone! I'm planing on making an intake plenum from carbon fiber and kevlar. It is for a turbocharged car, so it needs to withstand some pressure! The boost will be under 1 bar at the moment but I'm planning on testing the part on 3 bars at least, for reassurance. The parts will be made from heat resistant Vinylester probably, if not Epoxy resin and vacuum infusion. I'm planning on using 3 layers of 200gr 2X2 Twill Carbon fiber and 2 or 3 layers of hybrid 164gr Plain Carbon/Kevlar, alternatly in the layers. By that, I mean, the first layer will be Carbon fiber, then Carbon/Kevlar, then Carbon fiber etc etc. Will these layers and fabrics will be enough? Should I add anything or change any of the layers? Here is the 3D model of the parts in assembly.
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Hanaldo	Hanaldo posted 9 Years Ago HOT Post Details
Group: Forum Members Posts: 2.5K, Visits: 28K	I would probably build it a fair bit stronger than that to be honest, and probably ditch the Kevlar. Kevlar is only stronger than carbon once the laminate has failed, so it's really useful for holding parts together that may suffer breakage but in the case of a plenum it's much better to build a stronger part that just won't break. I would suggest aiming for a layup of around 1.5-2mm thick, and a bit beefier on any mounting points and the inlet if it's going to have a hose clamp on it. So my layup would probably be one layer of 200g, three or four layers of 450g, and then another layer of 200g for stability. Extra localised layer of 450 on the mounting points. Solid carbon.
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Carbon fiber intake plenum

Elias_GR - 9 Years Ago

I would probably build it a fair bit stronger than that to be honest, and probably ditch the Kevlar....

Hanaldo - 9 Years Ago

Thanks Hanaldo! I'm aiming for 2-2.5mm for total safety to be exact. Would it be better if i used...

Elias_GR - 9 Years Ago

For 2-2.5mm you will want 4 or 5 layers of 450 with a layer of 200 on either side. Alternatively 3-4...

Hanaldo - 9 Years Ago

I made a carbon plenum for my noble over the past 8 months... not bonded it together but its strong...

andygtt - 8 Years Ago

I would echo above, I didn't use any kevlar..... Id also make it in PrePreg as I wanted to cure it...

andygtt - 8 Years Ago

Thanks a lot for the replies! You've done a really nice work on the intake plenum there Andy! I...

Elias_GR - 8 Years Ago

I'm in the same boat I want to create a plenum fairly soon but I don't have access to a prepreg...

davro - 8 Years Ago

I was thinking exactly the same thing yesterday, about the heat reflective materials. The one...

Elias_GR - 8 Years Ago

Bit of an older post, however I could use some suggestions in materials for heat reflection. Suggestions appreciated.

Jadleybray - 8 Years Ago

You really should be ok, you may just suffer a bit of print-through. I've made plenty of engine bay...

Hanaldo - 8 Years Ago

Hanaldo thanks for the reply! The resin I'm going to use has 123C Tg, so the only thing "I'm most...

Elias_GR - 8 Years Ago

I built myself an oven purely so I could make the plenum in prepreg, it was my first ever part in...

andygtt - 8 Years Ago

So after quiet a while I found some time to continue the project! Yesterday i got the plugs from the CNC and I've already started to seal the wood so I can produce a mold. I'll get back with plenty o...

Elias_GR - 7 Years Ago

Good stuff mate, man CNC's make this game too easy! Haha. Interesting plenum design, I hadn't realised from your drawing it was such a tight area at the back. what sort of engine is it for?

Hanaldo - 7 Years Ago

Thanks Hanaldo! CNC's are really an enormous help! The intake will be put in a small Nissan engine, for some tests and the we will upscale it for (hopefully) something better. Also if anyone has...

Elias_GR - 7 Years Ago

Interesting... CA, SR? Or something less mainstream? The build thread for my oven is here http://www.talkcomposites.com/21047/MDF-Curing-Oven?PageIndex=1 Still working like a charm, and I'm...

Hanaldo - 7 Years Ago

Hanaldo this will be tested on my ''lab rat'' which is a GA series motor that I've boosted a couple of years ago. Very helpful thread for the oven! Thanks! A bit more progress now. I sealed the MDF...

Elias_GR - 7 Years Ago

Nice project, I am waiting for more photos. 1.5-2 mm will be quite enought for the wall thickness.

ArturK - 7 Years Ago

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