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Building Integrity
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Date: 7-25-2014
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Number of Hours: 9.00
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Manual Reference: Section 2
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Brief Description: Plenum and intake design finalized
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The cooling plenums have been curing for about 5 days now so It's time to remove the foam and tape. I laid up the glass over the aluminum thinking I'd get a good enough bond and quickly found out that was very untrue. It popped off like I had spread mold release on it but didn't. I then had to decide how the fiberglass would attach to the aluminum. I knew that using nutplates and screws would work, but that in order to attach it at all the corners and be able to remove it, the entire assembly would have to come off first. This makes for good reason to make the 2 pieces permanent. Resin is out of the question, which leaves me with my solution. A small bead of Red RTV along the adjoining border, then adding small flush rivets along the lip. The rivets will only create very minor turbulence inside the plenum compared to all the plugs, wires, sensors and every other odd shaped item already in there. I can then add filler to the weave and a smooth radius where it meets the aluminum for a pretty good look. Ideally, the entire box would be composite, and they very well may become that way if UL Power takes a liking to all this design work I'm doing.
Next I wanted to tackle this "throttle body intake filter" ghost that has been hiding in the closet for almost a year. The filter they use for the 4 cylinder engines, bolts right onto the throttle body. HOWEVER, the 6 cylinders require a massive hose that is suppose to connect to the filter somewhere inside the cowling. Nasty and I don't have room. Well I found that adding a section of silicone tubing to the firewall opening happened to be the perfect adapter for the UL power 60mm tubing. I can now run 1 section of tubing directly to the firewall. Inside, there will be a SS mesh that helps to filter out any "large" unwanted items. However, the intake opening on top is a MUCH cleaner air source than the typical belly scoop.
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Glass removed and trimmed up
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Openings for plug and sensor wires
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looking custom baby!
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