SUPERCHARGER - Page 28

MANDALAY · 11-04-2009, 04:42 AM

Quote:

Originally Posted by Roman

Aaah, right! I see.

Oh one thing i forgot to mention, after pushing the fitting through the bottle which be very tight run a bead of liquid teflon around the base then put the washer on then the nut. Added security as it will squezze though any voids just in case

MANDALAY · 11-09-2009, 05:24 AM

While my block is being put together and machining of the bracket for my water bottle i thought i would start the next mini project , the under trays

MANDALAY · 11-09-2009, 05:25 AM

Here is a picture of the bottom of my car with the trays removed.
Pretty busy under there with little room to add 2 19 mm aluminium/ copper pipes for my A/W set up.
I could have run them outside the covers but dont like that idea, so the only option is to make new trays with a bump for the 2 pipes.
After thinking about this for a while i came up with this method.
Firstly to make moulds of the plastic trays , good idea but with one problem , they are flimsy and would move and wont mount in the right location( been there done that many years ago )
So what i did was to mount L shaped made brackets to all the mounting holes,
them bog pieces of MDF to these brackets and join them all together,
That way i would have a jig of the bottom of the car.
The trays would be mounted to this jig. This way there wont be any movement and all the locations would be spot on.
To simplify things i pop rivited 3 of the parts so as to make one part.
So the next step is to make the mould. I used 2 part epoxy and HEAVY carbon fibre. I laminated 4 layers as to make a very strong rigid mould.
Once i clean up the mould ill add the tunnel for the 2 pipes. Once done i can finally make the finished article. When i have time ill make the other panels the same way.

Breed-X · 11-09-2009, 02:41 PM

dude thats going to look

killermillermr2 · 11-09-2009, 02:45 PM

puretone · 11-09-2009, 05:14 PM

carbon fiber/fibre, what is that?

DUDE WHAT>?!

MANDALAY · 11-09-2009, 07:27 PM

I used even Carbon fibre for the mould ,reason well it was real cheap because the seller has a xxxxload that he doesnt selll of that grade 1200 gsm. Well is great for building up thickness

MANDALAY · 11-10-2009, 05:13 AM

Got my latest toy.
Well to add the A/W radiator up front you have to move the 2 horns. Since i have to do that i thought may as well replace them . Might sound a bit weird but i love the sound of FERRARI'S air horns of the70 - 80's. They are the genuine things from FERRARI . Lamborghini used the same horns also.

Quandry · 11-11-2009, 03:44 AM

hmm...

Air horns -5
The fact that they are Ferrari genuine +5
Total 0

You come out about even in my book.

MANDALAY · 11-11-2009, 06:21 AM

but i really do like the characterist sound

Quandry · 11-11-2009, 02:51 PM

hmm, I had air horns on my Celica about 17 years ago. I hope they sound better than those did

Remember to put a good relay before the compressor otherwise they loose a bit of pep

puretone · 11-11-2009, 10:12 PM

I wish you had said they are from a Lamborghini and Ferrari (being the nasty copycats they are....) has them too....

What? Too cool for General Lee horns? Dukes of Hazzard General Lee Dixie Car Horn - WOL430

Hey MANDALAY, the MDF jig you made, you added the L brackets & all that to get the general shape of what the undertray would need to hang from? At first I thought you were making the whole try from scratch until I actually read your post (AAAAND gave up for a sec looking for the bit where you say its finally ready....) and saw you are using the OEM one popped together as a mold instead.....I was thinking of doing the same with my from end because of the new WRC bumper I have and the mounts for an engine bay "shroud" not really existing.....

Juuuuust an observation, BUT, MANDALAY, you should make a few more of these and sell them to some USA kiddies that like to mess with the undersides of their MR2's, you could probably sell them for ALOT.

MANDALAY · 11-11-2009, 11:57 PM

It was easier to join 3 of the pieces . This way i can shape it a bit better. Toyota put creases into the panels to add some stifness which i dont need give that mine will be made from Carbon Fibre and Epoxy.

Which BTW use epoxy for your laminating resin. Very hight temp resistant.
If you have never used it before in your famous words
GOOGLE !!
There are a few good videos on line.

Man to ship a part that big would cost a fortune even though it couldnt weigh more than 500 grams.

Musical horns are not allowed to be the factory horn.

Apart that i like the FERRARI frequency of their horn, they are loud.

Horns are very efficient and amplify the sound. Hey ive got horns in my sound quality BMW.

puretone · 11-14-2009, 10:26 PM

Quote:

Originally Posted by MANDALAY

It was easier to join 3 of the pieces . This way i can shape it a bit better. Toyota put creases into the panels to add some stifness which i dont need give that mine will be made from Carbon Fibre and Epoxy.

Which BTW use epoxy for your laminating resin. Very hight temp resistant.
If you have never used it before in your famous words
GOOGLE !!
There are a few good videos on line.

Man to ship a part that big would cost a fortune even though it couldnt weigh more than 500 grams.

Musical horns are not allowed to be the factory horn.

Apart that i like the FERRARI frequency of their horn, they are loud.

Horns are very efficient and amplify the sound. Hey ive got horns in my sound quality BMW.

I used to help build surf/windsurf & now kite boards with my brother in law....all carbon, carbon-kevlar (might not be bad idea for you, one layer of kev that faces the road....) & kevlar sandwiched with Divinycell and/or HoneyComb aramid core boards.....3.5 lbs surf board was KILLER, though too light....built some 1/8 scale nitro remote control car chasis too....high heat epoxy was key, cured in 150 degree C oven....

They charge you guys dimensional weight?? Thats from the English empire days, what the hellllll??!!!!

Funny thing is, I'm fed up with the lacks fitment of the current "under tray" I have combined with the WRC bumper I have....thinking of fabbing up a engine bay tray myself now....

MANDALAY · 11-15-2009, 12:47 AM

Here is the mould made.
Now i can make the finished article . Finally !

puretone · 11-15-2009, 06:50 PM

She's a purrrdy beaut!

MANDALAY · 11-19-2009, 10:04 PM

So im doing another modification to the plan.
First was the hoses to custom made ones , next was the water bottle for the A/W system and oil catch can resivour.
Now the only thing that has plagued me is that even though the Rotrex has its belt wrapped around like 300 degress, it only being a PK4 troubled me.
A solid billet crank pulley was a no go. I wanted the rubber insert / balancer as the OEM. I searched for months to see if any one makes them. Numerous forums and google searches to no avail...............................
Well last night i accidentally stumbled on a sight......................
DAM and there here in Australia !!!!!!!!!!!!!! and building for 30 years.
Well ive sent them the OEM unit and im getting one made so the ROTREX will have a PK6 and the A/C , alternater and tensioner will have a PK4. When thats done ill have to extend the pullies on the A/C , alternater and tensioner.
Well PK6 with 300 degrees wrap can easily handle 600 horses which mine wont be.

Breed-X · 11-20-2009, 04:38 PM

nice keep the pics coming

njccmd2002 · 11-20-2009, 10:45 PM

wow amazing, love the new ideas...

MANDALAY · 11-21-2009, 04:40 AM

Started on the piping.
First i made some brackets to hold the 3/4 inch aluminium pipe work.
They are mounted strategically at various points all the time using locations that have bolts already.
For under the fuel tank locations are . on the fuel tank bracket while the other one is on the x-member under the fuel tank.
Im using dowel to get the overall shape , which then will be bent in aluminium.

11-09-2009, 05:25 AM	#543 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	Here is a picture of the bottom of my car with the trays removed. Pretty busy under there with little room to add 2 19 mm aluminium/ copper pipes for my A/W set up. I could have run them outside the covers but dont like that idea, so the only option is to make new trays with a bump for the 2 pipes. After thinking about this for a while i came up with this method. Firstly to make moulds of the plastic trays , good idea but with one problem , they are flimsy and would move and wont mount in the right location( been there done that many years ago ) So what i did was to mount L shaped made brackets to all the mounting holes, them bog pieces of MDF to these brackets and join them all together, That way i would have a jig of the bottom of the car. The trays would be mounted to this jig. This way there wont be any movement and all the locations would be spot on. To simplify things i pop rivited 3 of the parts so as to make one part. So the next step is to make the mould. I used 2 part epoxy and HEAVY carbon fibre. I laminated 4 layers as to make a very strong rigid mould. Once i clean up the mould ill add the tunnel for the 2 pipes. Once done i can finally make the finished article. When i have time ill make the other panels the same way. Last edited by MANDALAY; 11-09-2009 at 07:26 AM.

11-15-2009, 12:47 AM	#555 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	Here is the mould made. Now i can make the finished article . Finally ! Last edited by MANDALAY; 11-15-2009 at 08:33 AM.

11-21-2009, 04:40 AM	#560 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	Started on the piping. First i made some brackets to hold the 3/4 inch aluminium pipe work. They are mounted strategically at various points all the time using locations that have bolts already. For under the fuel tank locations are . on the fuel tank bracket while the other one is on the x-member under the fuel tank. Im using dowel to get the overall shape , which then will be bent in aluminium. Last edited by MANDALAY; 11-21-2009 at 04:58 AM.

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11-09-2009, 05:24 AM	#542 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	While my block is being put together and machining of the bracket for my water bottle i thought i would start the next mini project , the under trays

11-09-2009, 02:41 PM	#544 (permalink)
Breed-X Breed-Xtreme Performance Join Date: Nov 2006 Location: Belgium Posts: 79 Thanks: 0 Thanked 3 Times in 3 Posts My Google Map iTrader Rating: (0/0% )	dude thats going to look

11-09-2009, 02:45 PM	#545 (permalink)
killermillermr2 Honda Hunter Join Date: Dec 2007 Location: Colorado Posts: 701 Thanks: 22 Thanked 22 Times in 22 Posts iTrader Rating: (6/100% )

11-09-2009, 05:14 PM	#546 (permalink)
puretone Beams Owners Group Join Date: Aug 2006 Location: Aruba, #1 BEAMS Engine on the Island Posts: 1,352 Thanks: 24 Thanked 46 Times in 45 Posts My Google Map iTrader Rating: (0/0% )	carbon fiber/fibre, what is that? DUDE WHAT>?!

11-09-2009, 07:27 PM	#547 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	I used even Carbon fibre for the mould ,reason well it was real cheap because the seller has a xxxxload that he doesnt selll of that grade 1200 gsm. Well is great for building up thickness

11-10-2009, 05:13 AM	#548 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	Got my latest toy. Well to add the A/W radiator up front you have to move the 2 horns. Since i have to do that i thought may as well replace them . Might sound a bit weird but i love the sound of FERRARI'S air horns of the70 - 80's. They are the genuine things from FERRARI . Lamborghini used the same horns also.

11-11-2009, 03:44 AM	#549 (permalink)
Quandry No Skills Join Date: Jul 2009 Posts: 19 Thanks: 1 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	hmm... Air horns -5 The fact that they are Ferrari genuine +5 Total 0 You come out about even in my book.

11-11-2009, 06:21 AM	#550 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	but i really do like the characterist sound

11-11-2009, 02:51 PM	#551 (permalink)
Quandry No Skills Join Date: Jul 2009 Posts: 19 Thanks: 1 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	hmm, I had air horns on my Celica about 17 years ago. I hope they sound better than those did Remember to put a good relay before the compressor otherwise they loose a bit of pep

11-11-2009, 10:12 PM	#552 (permalink)
puretone Beams Owners Group Join Date: Aug 2006 Location: Aruba, #1 BEAMS Engine on the Island Posts: 1,352 Thanks: 24 Thanked 46 Times in 45 Posts My Google Map iTrader Rating: (0/0% )	I wish you had said they are from a Lamborghini and Ferrari (being the nasty copycats they are....) has them too.... What? Too cool for General Lee horns? Dukes of Hazzard General Lee Dixie Car Horn - WOL430 Hey MANDALAY, the MDF jig you made, you added the L brackets & all that to get the general shape of what the undertray would need to hang from? At first I thought you were making the whole try from scratch until I actually read your post (AAAAND gave up for a sec looking for the bit where you say its finally ready....) and saw you are using the OEM one popped together as a mold instead.....I was thinking of doing the same with my from end because of the new WRC bumper I have and the mounts for an engine bay "shroud" not really existing..... Juuuuust an observation, BUT, MANDALAY, you should make a few more of these and sell them to some USA kiddies that like to mess with the undersides of their MR2's, you could probably sell them for ALOT.

11-11-2009, 11:57 PM	#553 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	It was easier to join 3 of the pieces . This way i can shape it a bit better. Toyota put creases into the panels to add some stifness which i dont need give that mine will be made from Carbon Fibre and Epoxy. Which BTW use epoxy for your laminating resin. Very hight temp resistant. If you have never used it before in your famous words GOOGLE !! There are a few good videos on line. Man to ship a part that big would cost a fortune even though it couldnt weigh more than 500 grams. Musical horns are not allowed to be the factory horn. Apart that i like the FERRARI frequency of their horn, they are loud. Horns are very efficient and amplify the sound. Hey ive got horns in my sound quality BMW.

11-15-2009, 06:50 PM	#556 (permalink)
puretone Beams Owners Group Join Date: Aug 2006 Location: Aruba, #1 BEAMS Engine on the Island Posts: 1,352 Thanks: 24 Thanked 46 Times in 45 Posts My Google Map iTrader Rating: (0/0% )	She's a purrrdy beaut!

11-19-2009, 10:04 PM	#557 (permalink)
MANDALAY Beams Owners Group Join Date: Feb 2007 Location: victoria AUSTRALIA Posts: 1,830 Thanks: 88 Thanked 64 Times in 60 Posts My Google Map iTrader Rating: (4/100% )	So im doing another modification to the plan. First was the hoses to custom made ones , next was the water bottle for the A/W system and oil catch can resivour. Now the only thing that has plagued me is that even though the Rotrex has its belt wrapped around like 300 degress, it only being a PK4 troubled me. A solid billet crank pulley was a no go. I wanted the rubber insert / balancer as the OEM. I searched for months to see if any one makes them. Numerous forums and google searches to no avail............................... Well last night i accidentally stumbled on a sight...................... DAM and there here in Australia !!!!!!!!!!!!!! and building for 30 years. Well ive sent them the OEM unit and im getting one made so the ROTREX will have a PK6 and the A/C , alternater and tensioner will have a PK4. When thats done ill have to extend the pullies on the A/C , alternater and tensioner. Well PK6 with 300 degrees wrap can easily handle 600 horses which mine wont be.

11-20-2009, 04:38 PM	#558 (permalink)
Breed-X Breed-Xtreme Performance Join Date: Nov 2006 Location: Belgium Posts: 79 Thanks: 0 Thanked 3 Times in 3 Posts My Google Map iTrader Rating: (0/0% )	nice keep the pics coming

11-20-2009, 10:45 PM	#559 (permalink)
njccmd2002 Beams Owners Group Join Date: May 2008 Location: Jackson TN Posts: 69 Thanks: 8 Thanked 1 Time in 1 Post iTrader Rating: (0/0% )	wow amazing, love the new ideas...