Quote from: redhenracing2 on December 03, 2010, 02:46:04 PM
A buddy of mine with a turbo miata has a very small intercooler, but I think it's about the same as the one already being used here.

Yeah I googled jet ski intercoolers but they're all water to air which of course wont work.

Quote from: redhenracing2 on December 03, 2010, 02:46:04 PM
Cool beans. Are you gonna clear them or coat it in more resin?

Both most likely. There are a couple low spots/pin holes that need a bit more resin to fill them in anyway.

What would be really cool (yet kind of ruin it at the same time) would be to go over it with a candy coat (a very light coat) to give it some color but still have the carbon look . . . just a thought. I guesss it would look like Joe Rocket's line of colored carbon fiber helmets.

Quote from: redhenracing2 on December 03, 2010, 04:19:10 PM
What would be really cool (yet kind of ruin it at the same time) would be to go over it with a candy coat (a very light coat) to give it some color but still have the carbon look . . . just a thought. I guesss it would look like Joe Rocket's line of colored carbon fiber helmets.

That's what colored carbon kevlar is for. They dye a kevlar cross weave to give it some color.


I have a couple rolls of the stuff... Pretty cool

Making carbon pipes part 2:

This is the carbon I'm using.


It's basically woven into a sleeve. Imagine a sock basically.

It stretches width wise pretty wide.


Take the earlier made foam pipe and cover it with a layer of carbon.


Resin is then worked into the carbon. Basically add a little, rub it in, working from the middle out. This gets rid of any air bubbles and compacts the layers together.
This is done for all the layers. I'm using 3 here because of how tight the weave is on this small of a pipe.

After, the pipe is tightly wrapped in several layers of peel ply.


This further compacts the layers, squeezes out any extra resin or air bubbles, and holds everything to the foam shape. Normally I use a special type of heat shrink for this, but I can't seem to find mine.

From here, the part is heated and left to cure for several hours.

Carbon charge pipes part 3:

Resin is hard. Pulled the peel ply off. 4 layers wrapped tightly = pain in the ass to remove.

Fresh out of the peel ply.

At this point, you're saying... "but wait, these are wrapped around foam stupid!"

The amazing part about polystyrene foam is that it's soluble in gasoline or acetone. Pour some gas in, let it sit, and all the foam dissolves away.


Also finished the plug for the other charge pipe.

The tight u bend at the end had to be carved out of a block of foam. Very tedious.

I don't guess there's any way around that tight u-turn, seems like it would really reduce the efficiency of it. I'm just gonna stay out of it .  . . .you got this.   

Quote from: redhenracing2 on December 03, 2010, 09:13:52 PM
I don't guess there's any way around that tight u-turn, seems like it would really reduce the efficiency of it. I'm just gonna stay out of it .  . . .you got this.   

No way around it. I expanded the diameter through the u turn a bit as well which should help.

 

that is the most technologically advanced GS mod I have seen so far.

I have seen some mechanically complex mods (czoko, jim knopf etc), but this one is truly one of a kind!

great progress!
Keep up the great work and awesome pics!

Quote from: kml.krk on December 04, 2010, 12:02:40 PM
that is the most technologically advanced GS mod I have seen so far.

I have seen some mechanically complex mods (czoko, jim knopf etc), but this one is truly one of a kind!

great progress!
Keep up the great work and awesome pics!

Yeah I agree. Although there is a FI turbo GS running around somewhere.

Quote from: GI_JO_NATHAN on December 04, 2010, 03:37:30 PM
Yeah I agree. Although there is a FI turbo GS running around somewhere.

But is one of his cylinders acting as a compressor? I would say this one takes it a step further. Right up there with Jim. Put them together on a project and see what happens   

I know Im a little late beings how youve already done a crap load of work but I was also think up front lower to the bottom with inlet outlet facing up. But roll with what ya got. Cant wait to see this thing in action.

Quote from: Chanse on December 06, 2010, 04:50:16 PM
I know Im a little late beings how youve already done a crap load of work but I was also think up front lower to the bottom with inlet outlet facing up. But roll with what ya got. Cant wait to see this thing in action.

Really doesn't fit too well there... has to be way down on the ground to clear the wheel and right next to the exhaust would heat things up quite a bit.

Everything looks better with some gloss to it

Indeed it does. What did you use?

Quote from: saxman on December 03, 2010, 08:59:44 PM

The amazing part about polystyrene foam is that it's soluble in gasoline or acetone. Pour some gas in, let it sit, and all the foam dissolves away.

Yeah, polystyrene dissolved in gasoline or kerosene is not too dissimilar to napalm.

Quote from: redhenracing2 on December 10, 2010, 04:28:10 PM
Indeed it does. What did you use?

Just a light coating of resin, heated up a bit so it's self leveling.

Is there any advantage to doing that versus a clear coat? Extra strength maybe?