Soooo...I'm bored of waiting for Skunk2, so I am going to produce my own H22a manifold in a composite material. So engineers or whatever let's do some brainstorming.

Here are some pics of the ENDYN B-series CF intake manifold:








Now I plan to copy the OEM Euro-R manifold, and just port it and such...but My main question is how to attach the metal flanges to the composite material? I won't be using CF...but this wicked composite from another industry. Now what can we do to secure this **** together?

The only Idea I have so far is the build on a sort of re-bar mesh on the flange, that the composite material surrounds like is done in concrete forming....

Please any ideas would be great.

 

what sort of composite are we lookin at here? right now. i'm a little stumped. but the best thing i can think of is to form a "skeleton" of either a mesh as you stated. or of sheet metal. something that the composite could "grab" on to.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by stockludesi &raquo;</TD></TR><TR><TD CLASS="quote">what sort of composite are we lookin at here? right now. i'm a little stumped. but the best thing i can think of is to form a "skeleton" of either a mesh as you stated. or of sheet metal. something that the composite could "grab" on to.</TD></TR></TABLE>

The composite is hush hush, but it will hold on it's own. I am thinking I would just figure out a way to drive some screws/plugs into it during molding that we attach to the flanges, I'll think of something.

 

fiberglass would hold the same. if that's so hush hush.. i know how to make it (im) so easy it's funny... but i opted for something different....

i'll give you a hint, you can make one, or many but you need to make two molds.. one outermold, this would be the ouside dimensions of what your making.. for example if you are going to build runners, this is what you'd shape... so it looks like the inside of it.... you'd build one to make more... (ceramic or something similiar etc) i'd do it so i can remove it in two peices...

then get some plaster (wall stuff) then poor it into the mold for the runners, bake it, afterwards pull off the two outside peices, and you have the inner shape of the runner, smooth, and perfect, duplicate this 4 times for each runner, do the same for the plenum don't forget to mesure for the runners... then all you do is assemble the plaster (together) glue gune or what not where it doesn't affect the outershape and then attach your "alumum flange" and then either fiberglass it or carbon fiber it... after it's all done... dunk the whole thing in water and preffereably something that vibrates to disolve the plaster (don't use washing machine)

ahhaahah

and theire you have it.. how to do an IM in less than 3 days in CF or fiberglass. if somebody want's to start a project i have a aluminum prelude h22a flange with injector boss and 1 inch extension to mate in. machined and portmached to gasket with injector boss... polished.

how this helps joel

i'm sure theirs other ways but for simplicity (this one takes the cake)

 

oh ... and reason why i haven't done this yet? hehehe... i'll who you my im, in about a couple days with pictures...

having a aluminum tig welder is THa Bomb for this stuff!! =0)

 

Sounds like a great plan srv.

Just start playing with some molds, and try the re-bar idea.

It's about the only way I can think to secure it as well.