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GT500R

Fresh Air Intake Mod

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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. ūüėČ

Edited by Xtra
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Here is a sample of one of the materials that we are testing. It has a textured finish and smooth on the opposite side. 

76901_1000.jpg

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Yes, it is a heavy-duty form of an acrylonitrile butadiene styrene thermoplastic polymer.  :)

Edited by Xtra
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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.

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The shop got around to testing the mold and it worked great!  :happyfeet: 

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. :)

 

 

 

                                                                                                                         XTRA'S IONTAKE, FIRST TEST IN CLEAR FOR FITMENT.JPG    

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Fantastic news!  Looking forward to seeing it installed.

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Thank you handfiler for your encouragement, I can use it.  Progress is being made. I sure hope it fits after all this work.... 

IMG_5709.JPG

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It fits.... and the hood closes.:headspin: 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 

XTRA'S INTAKE 1.JPG

 

 

 

In this photo, you can see how the holes line up for the hood release and bump stops. 

XTRA'S INTAKE 2.JPG

 

 

 

 

The cardboard shows where the air enters then moves across to the snorkel.

EXTRA'S INTAKE 3.JPG

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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!¬†ūüćĽ

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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!¬†ūüćĽ

 

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 by Xtra

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I just realized that this project started in June 2019 and should be completed by December 2020.  That is 18 months if I count correctly, one and one-half years to get to this point.  That includes design, starting from clay, and several months of testing the fiberglass prototype for proof of concept. 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 by Xtra
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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.

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Great¬†minds think alike¬†. ūüėā

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. 

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Hope¬†everyone had a wonderful¬†Thanksgiving . My new material supplier is working with me to bring the bling ūü§Ď. Hopefully a sample sheet should be arriving next week. If it does then I will make 2 units, one of each finish.

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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..

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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.... 

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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. 

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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 :chacha:.   WWWPerfA_ZNOW I checked for you and unfortunately, sprinkles are not an option at this time...:reading: 

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bump

Edited by Xtra

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