Xtra Posted November 20, 2020 Report Share Posted November 20, 2020 (edited) It is looking like it is not going to happen this week, the shop is just to busy with making Covid Shields. Not all progress has stalled though. I have been working on, and have located, a new material supply vendor that is looking very good. ? Edited November 20, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 21, 2020 Report Share Posted November 21, 2020 Here is a sample of one of the materials that we are testing. It has a textured finish and smooth on the opposite side. 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted November 22, 2020 Report Share Posted November 22, 2020 plastic? Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 22, 2020 Report Share Posted November 22, 2020 (edited) Yes, it is a heavy-duty form of an acrylonitrile butadiene styrene thermoplastic polymer. Edited November 22, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted November 22, 2020 Report Share Posted November 22, 2020 Anti Breakage Stuff? Cool! 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 22, 2020 Report Share Posted November 22, 2020 (edited) 10 hours ago, WWWPerfA_ZN0W said: Anti Breakage Stuff? Cool! I believe it is the same material that the engine cover and the air duct that I am modifying are made of. Edited November 22, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 25, 2020 Report Share Posted November 25, 2020 (edited) The shop got around to testing the mold and it worked great! There were no problems with the vacuum, and the positive air input I added to pop the part off of the mold worked so well that the shop will be adding that feature to their molds. I still need to trim, locate and drill the mounting holes, and test for fit. Hopefully, can get it done by the end of the day because tomorrow is Thanksgiving. Edited November 25, 2020 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
handfiler Posted November 25, 2020 Report Share Posted November 25, 2020 Fantastic news! Looking forward to seeing it installed. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 25, 2020 Report Share Posted November 25, 2020 (edited) Thank you handfiler for your encouragement, I can use it. Progress is being made. I sure hope it fits after all this work.... Edited November 25, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 25, 2020 Report Share Posted November 25, 2020 (edited) It fits.... and the hood closes. I am over the top happy with the results. With the first one being transparent it was clear that there were no interference problems..... LOL In this photo, you can see how the holes line up for the hood release and bump stops. The cardboard shows where the air enters then moves across to the snorkel. Edited November 25, 2020 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
handfiler Posted November 26, 2020 Report Share Posted November 26, 2020 Nothing like having a clear component for doing the final fit and clearance analysis. This was a major project that had a very successful outcome. Congratulations on a job well done! ? 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 26, 2020 Report Share Posted November 26, 2020 (edited) 31 minutes ago, handfiler said: Nothing like having a clear component for doing the final fit and clearance analysis. This was a major project that had a very successful outcome. Congratulations on a job well done! ? Thank you so much, you are correct, it has been quite a journey to get to this point, and I agree, having a clear component cost me some $$ but it was well worth it. Just got back from a test run and it works as intended. Although the clear intake works, the next step is to make the real thing with much better cosmetics. TBC Edited November 26, 2020 by Xtra Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 26, 2020 Report Share Posted November 26, 2020 (edited) I just realized that this project started in June of 2017 and should be completed by late December 2020. Almost 3 1/2 years to get to this point if I counted correctly. That includes my first mod to the grill as mentioned at the start of this thread, the design of the intake starting from clay, and several months of testing the fiberglass prototype for proof of concept, and making the mold. Overall, I am very satisfied with the look and quality of the part. It does not have the very fine detail of an OEM pressure molded part, but it still way better than the fiberglass prototype, and it did not cost $15,000 or $20,000 for the mold. Still, IMHO the quality is as good as any vacuum formed part available. To me, it still has some of that hand made feel to it, not computer / digitally perfect, more organic. Edited December 5, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
dajo2012 Posted November 26, 2020 Report Share Posted November 26, 2020 Well done! 1 Quote Link to comment Share on other sites More sharing options...
omar302 Posted November 26, 2020 Report Share Posted November 26, 2020 7 hours ago, Xtra said: I still need to trim, locate and drill the mounting holes, and test for fit. Hopefully, can get it done by the end of the day because tomorrow is Thanksgiving. May I suggest you add some indentations on the mold were the holes would be so that they would be easily located after making the product? Or maybe screw in screws so holes are ready? I am sure this is something you probably had it in mind, just in case. 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 26, 2020 Report Share Posted November 26, 2020 Great minds think alike . ? You are correct that was one reason for clear, to locate the holes and then transfer them onto the mold. The plan is to drill dimples, if that doesn’t work then I will try round head screws as markers. 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 27, 2020 Report Share Posted November 27, 2020 (edited) Hope everyone had a wonderful Thanksgiving . My new material supplier is working with me to bring the bling ?. Hopefully a sample sheet should be arriving next week. If it does then I will make 2 units, one of each finish. Edited November 27, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 27, 2020 Report Share Posted November 27, 2020 (edited) The problem is in trimming the intake. It is done by hand, each one is a little different, and it takes time . That is not a bad thing but, these will never be 100% flawless and perfect . After all they are homemade. And people now days are accustomed to perfect flawless products made by robots in huge facilities. I have been working close with the shop trying to get the best price, and it is looking like runs of 5 or ten will be necessary to do that. Heck, I don’t know if anyone is even interested.. Edited November 27, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
CrackedDSM Posted November 27, 2020 Report Share Posted November 27, 2020 I’m interested. Especially in a clear one. Lol 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 28, 2020 Report Share Posted November 28, 2020 4 hours ago, CrackedDSM said: I’m interested. Especially in a clear one. Lol Lol, I hear you. Within the next couple of weeks, I intend to bring the bling.... 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted November 28, 2020 Report Share Posted November 28, 2020 I want mine with sprinkles please. 1 Quote Link to comment Share on other sites More sharing options...
CrackedDSM Posted November 28, 2020 Report Share Posted November 28, 2020 12 hours ago, Xtra said: Lol, I hear you. Within the next couple of weeks, I intend to bring the bling.... I know I said lol, but I’m actually serious. I really like the clear look. I don’t know why. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 28, 2020 Report Share Posted November 28, 2020 (edited) 1 9 hours ago, CrackedDSM said: 9 hours ago, CrackedDSM said: I know I said lol, but I’m actually serious. I really like the clear look. I don’t know why. CrackedDSM, I will be able to make them in clear, and in black. The bling that I have mentioned, but have not tested yet is, ....Carbon Fiber !! Not just Black but in Red and White Carbon Fiber as well . WWWPerfA_ZNOW I checked for you and unfortunately, sprinkles are not an option at this time... Edited November 29, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted November 29, 2020 Report Share Posted November 29, 2020 (edited) UPDATE : I had originally ordered the sample of the special carbon material on 11-14 and they just shipped it today 12-2, and it won't arrive until the middle of next week 12 -9. If this new carbon material works as intended then the lead time on the carbon part is now up to 3 to 4 weeks. The black and clear are in stock and ready to go. I am just waiting on the carbon, and when it arrives I will make two samples, one in black and one in carbon fiber. That way I can save on the setup expense. Hopefully, during the week of 12-14 to 12-18, the sample intakes will be done. Edited December 2, 2020 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted December 4, 2020 Report Share Posted December 4, 2020 (edited) Omar302, I took the mold home from the shop for some tweaking, and to add the hole marker screws. The screw heads will make a little bump on top and a little indention on the backside that I can use to guide the drill. Hopefully, the placement of the screws are spot on... We will see on the next intake just how accurate they are, if necessary they can always be adjusted. Edited December 4, 2020 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
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