custom intake for 3.4dohc turbo

p8ntman442 · Post by **p8ntman442** » Wed Oct 26, 2005 7:39 pm

thats gonna get messy.

Kohburn · Post by **Kohburn** » Wed Oct 26, 2005 7:40 pm

heh thats why everything is covered in plastic wrap

Series8217 · Post by **Series8217** » Wed Oct 26, 2005 7:42 pm

NICE notchback, man. It's soooo tempting to go aero after seeing pics of all these sweet spoilerless aero notchies..

Aaron · Post by **Aaron** » Wed Oct 26, 2005 8:41 pm

Wow, uhhh, that's one ugly ass intake manifold...

Sorry, I'll stick with stock.

lol j/k, looking good so far, I guess...I'll be impressed when it's done and looks good though. Hold off on sending me the factory UIM until you have it up and running though, just to be safe. I'd like to get the UIM sometime mid-December.

Post by **eHoward** » Wed Oct 26, 2005 8:44 pm

wow.

Good luck.

Kohburn · Post by **Kohburn** » Thu Oct 27, 2005 7:23 am

due to low temps - as of this morning some of it still wasn't hardened and most of it had sagged.. I may have to start over on the foam or use foam thats already solid rather than expanding foam

we'll see if its hardened when I get home today as to weather or not I will have to start over on the foam

p8ntman442 · Post by **p8ntman442** » Thu Oct 27, 2005 7:39 am

my roomate kicked a hole in our door, and fixed it with that foam stuff, took about a week to harden, and we had about a square foot, 3 inches thick.

Kohburn · Post by **Kohburn** » Thu Oct 27, 2005 7:58 am

I realized the plastic wrap I put over it to keep it from getting things messy is probably keeping it from hardening.. may have to go pull that off when i get home -

The Dark Side of Will · Thu Oct 27, 2005 10:26 am

Using 3M Great Stuff?
Plastic wrap shouldn't have any effect at all. Put a heat lamp on it. Low temps REALLY slow down chemical processes like that.

Kohburn · Post by **Kohburn** » Fri Oct 28, 2005 9:06 am

The Dark Side of Will wrote:Using 3M Great Stuff?
Plastic wrap shouldn't have any effect at all. Put a heat lamp on it. Low temps REALLY slow down chemical processes like that.

pulled the foam off last night - only areas exposed to the air had cured - the rest was just sticky goop that when exposed to the air cured in about an hour, so yes the plastic wrap was the downfall - would have been better off using paper towels.

needless to say, that was a flop

however I started carving foam from green floral fome last night - forming actually trumpets for the runners with dividers to the top of the trumpets.. this method is going very well.. after its done i just have to seal it so the epoxy won't stick.. if all goes well I may have it done this weekend and can finally wrap up my tuning

donk_316 · Post by **donk_316** » Fri Oct 28, 2005 10:33 am

I applaud you for actually doing something as opposed to doing what alot of us do...

Talk about doing it and arguing the smallest detail...then doing nothing...

Right on man. Keep it up.

Kohburn · Post by **Kohburn** » Fri Oct 28, 2005 11:07 am

donk_316 wrote:I applaud you for actually doing something as opposed to doing what alot of us do...

Talk about doing it and arguing the smallest detail...then doing nothing...

Right on man. Keep it up.

:thumbleft:

it'll all be worth it once i get it tuned and dynoed

also once its complete i should be able to make ceramic molds and replicate it from cast aluminum (using melted down fiero engine parts

) so if I get to that stage i should have some sweet 3.4dohc intakes for sale

Oversteer · Post by **Oversteer** » Fri Oct 28, 2005 11:39 am

Can the spray foam your used be sanded?

Kohburn · Post by **Kohburn** » Fri Oct 28, 2005 12:20 pm

Oversteer wrote:Can the spray foam your used be sanded?

its a fairly dense closed cell foam - once its fully cured it can be carved/filed/sanded

the green foam is porous and weak, but it can be cut just by shoving a thin metal ruler through it - it only took me a few minutes to duplicate the intake runner trumpet once i had the first one worked up and test fitted in the engine bay to clear the fuel rail.

The Dark Side of Will · Fri Oct 28, 2005 12:21 pm

Kohburn wrote:
The Dark Side of Will wrote:Using 3M Great Stuff?
Plastic wrap shouldn't have any effect at all. Put a heat lamp on it. Low temps REALLY slow down chemical processes like that.
pulled the foam off last night - only areas exposed to the air had cured - the rest was just sticky goop that when exposed to the air cured in about an hour, so yes the plastic wrap was the downfall - would have been better off using paper towels.

Now that's strange. I spray it inside frame rails and it cures fine...

Kohburn · Post by **Kohburn** » Fri Oct 28, 2005 12:22 pm

The Dark Side of Will wrote:
Kohburn wrote:
The Dark Side of Will wrote:Using 3M Great Stuff?
Plastic wrap shouldn't have any effect at all. Put a heat lamp on it. Low temps REALLY slow down chemical processes like that.
pulled the foam off last night - only areas exposed to the air had cured - the rest was just sticky goop that when exposed to the air cured in about an hour, so yes the plastic wrap was the downfall - would have been better off using paper towels.
Now that's strange. I spray it inside frame rails and it cures fine...

interesting..you do that to keep moisture from getting to the inside of the rail?

whipped · Post by **whipped** » Fri Oct 28, 2005 1:33 pm

The Dark Side of Will wrote: Now that's strange. I spray it inside frame rails and it cures fine...

That you KNOW OF. I did the same thing, and only the top 1-1.5" or so cured. The middle was still soft.

Kohburn · Post by **Kohburn** » Fri Oct 28, 2005 1:40 pm

the 2 part mixture will cure all the way through - but the great stuff seems to rely on ambient air

The Dark Side of Will · Fri Oct 28, 2005 1:46 pm

I've had situations in which I had to go back into the frame rail (to install a hitch for instance) and the stuff was cured all the way through. I use the triple expanding variety. I don't know how that differs in terms of curing requirements from the minimal expanding variety, which it appears that you used.

Moisture mostly, but it has a few other debatable effects like NVH reduction and structural stiffening.

Blue Shift · Post by **Blue Shift** » Sat Oct 29, 2005 3:54 am

What is the Great Stuff? Some sorta Urethane? I always thought it cured by some reaction not unlike polyester resin does.

Perhaps its just a plastic dissolved into a solvent with a blowing agent/propellant mixed in? If that's the case, yea it's going to need to evaporate all the solvent out. It probably also means that you could melt it with the correct solvent, as well.