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Hanaldo
Hanaldo
posted 11 Years Ago
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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:
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:
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:
And the second one:
Plenums trimmed and polished up:
Then the airbox infused:
Bonded together:
Everything dummy fitted:
Airbox sprayed with Duratec Sunshield:
Then flatted back and polished:
Also made those carbon blanking panels to cover the empty spaces.
Finished off the engine bay with this carbon fibre fuse box cover
Not a bad looking way to make a naturally aspirated 1000rwhp!
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Hanaldo
Hanaldo
posted 11 Years Ago
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Some of you may remember this Motec electronic dash mount that I made awhile back:
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:
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Hanaldo
Hanaldo
posted 11 Years Ago
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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:
I'll update with photos as I progress.
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Brian2fast
Brian2fast
posted 11 Years Ago
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Hi Hanaldo
This is what we want! Lots of photographs of patterns, moulds and parts. Cool.
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
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TomDesign
TomDesign
posted 11 Years Ago
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ye already sended him PM
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Hanaldo
Hanaldo
posted 11 Years Ago
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Thanks guys
Tom, I will reply to your pm as soon as I can
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.
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Matthieu Libeert
Matthieu Libeert
posted 11 Years Ago
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good job! love to see projects like these
Matthieu Libeert
Founder MAT2 Composites X Sports
website:
www.mat2composites.com
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scottracing
scottracing
posted 11 Years Ago
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good work, i enjoy seeing the tooling nearly as much as the final parts!
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TomDesign
TomDesign
posted 11 Years Ago
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and looking forward on PM
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Hanaldo
Hanaldo
posted 10 Years Ago
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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:
Final product weighed 6.0kg, the original steel bonnet weighed in at 16.3kg, so managed to save 10.3kg and grow a bulge
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