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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andygtt	andygtt posted 8 Years Ago HOT Post Details
Group: Forum Members Posts: 157, Visits: 1.2K	I built myself an oven purely so I could make the plenum in prepreg, it was my first ever part in pre preg. Oven cost around £100-150 to build and around 15hrs.... worth it as I now post cute all my resin infusion parts as well. My oven is modular in design as I made the walls in 100mm cellutex and built the heating element and fan into a self made steel unit that I bolt into a cut out in the cellutex.... door is simply one of the sides that I push in and pull out and is just a push fit nothing flash. Hold temps very well, even overnight after it's turned off. I made it modular so I could easily change the size and shape of it, this one is only 900x900x800mm so I can't fit in my large rear spoiler hence I've built a coffin shaped over is same materials so I can cure the spoilers.
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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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