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Intake plenum
Intake plenum
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bytesandbolts
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bytesandbolts
posted 7 Years Ago
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I'm looking for some general advice on making an intake plenum to suit a low boost turbo engine (7 PSI) out of carbon fiber using vacuum infusion, utilising my 3D printer to create the mould. This would be the first carbon fibre part that I've made, based on a design drawn up in Autodesk Fusion 360 shown below.
So far I've spent a few days doing research online, reading other posts in this forum relating to intake manifolds and 3D printing moulds and watched numerous videos on producing carbon fibre parts. However I still have a few open points I'd like to get peoples opinion on.
Based on the plenum shape I'm assuming I would create a positive mould.
Should I use tooling gel or something like 3M Super 77 sparingly to ensure the CF attaches to the shape.
Does this sound right to create a 3D printed mould; use PLA filament, smooth down the edges, spray a few coats of plastic filler primer and seal with S120 mould sealer.
For the 4 bolt end flange I'm guessing this can't really be formed using CF. Instead could I go about inserting an aluminium flange that could form part of the mould and be covered in CF. Would this hold up under boost?
Layer up wall thickness to be around 2mm, from what I've read this would be strong enough.
I'm happy to post pics as I go a long, I'm currently doing prototype prints of the mould.
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Intake plenum
bytesandbolts
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7 Years Ago
-Are you sure, that you are able to get a positive mould out of the part? If so, a positive mould would be a good option. But resin infusion might be tricky either way. Possible, but no beginner part...
oekmont
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7 Years Ago
- Just to confirm my understanding, positive mould being layering on top versus into the mould correct. This prototype print is what a mould could look like, and I would be layering on the CF on top....
bytesandbolts
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7 Years Ago
A positive mould would be something you would remove after the resin has cured. This is just the part printed as you want it to be in the final shape, am I right? There is no way you could remove the...
oekmont
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7 Years Ago
An old post but, just in case the OP is still here. I would reconsider making the plenum out of carbon. A friend, who builds race cars, stopped me from doing just this. On a N/A engine there...
Steve Broad
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7 Years Ago
I'm sorry but that is far fetched... I build lots of carbon intake plenums as well as various other engine components for lots of different race cars, from little weekend 200hp NA Civic's, to 700hp.....
Hanaldo
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7 Years Ago
I would like to kind of disagree with both of you. -Except for interlaminar stress, carbon has excellent duration fatigue strength. And as the plenum should be under pressure from the turbo, I don't...
oekmont
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7 Years Ago
It happened, whether you believe it or not :-) However, it was a while ago so, hopefully, designs, techniques and materials have solved the issues. BUT, I think making one of these without the...
Steve Broad
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7 Years Ago
I've realised my earlier post probably came across as quite confrontational - probably a combination of having stayed up to watch the Germany game last night, as well as only being half way through m...
Hanaldo
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7 Years Ago
I do believe you that it happend. But it was likely a construction problem. Wrong shape or insufficient wall thickness. Maybe insufficient overlapping of the layers of a two part mold. As long as w...
oekmont
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7 Years Ago
Agree with the 'experienced laminators' statement, not something that I would take on as I value my engine too much :-)
Steve Broad
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7 Years Ago
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