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Beast_box, carbon DTM DCOE/ITB intake project


beast02er

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Well I have started a project making what I hope will turn out to be a DTM style airbox that will fit sidedraft webers AND ITB style set-ups. It will integrate the air horns (velocity stacks) and HOPEFULLY have a curve to it that will allow it to clear the stock brake booster and tii brake booster. I say hope.......because it is untested/unchecked.

As it sits, the plugs have been machined and have been sanded ready for resin coating for sealing.

If anyone is interested in purchasing, contact me by email. I am making 1/4" carbon flanges cut on a waterjet to mount to the weber bolt pattern (for velocity stacks), 10 total, 5 as 2 piece flanges, and 5 as 4 piece flanges. Hopefully all goes well with my molds and first parts. They will be resin infused carbon epoxy. Price will probably be in the $600-$750 range depending on what material costs come out to be ( I will have to wait and see how things go)

Anyway, check out the pictures, first pictures are of the CAD model with 2 piece flange, later pictures are crappy quality pictures of the machined plugs

Bryan

red73

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73' 2002 "red"

66' 2 Door Cortina GT

http://mk1cortinasearch.blogspot.com/

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Looking good but you dont have an email listed. I'd be interested in a set that would fit a dual sidedraught 40/40 DCOM. A picture of my engine compartment and brake booster is attached. I now run a strut bar which is not pictured, would your design accommodate?

Thank you. My email is rs235 atcolumbia.edu.

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1976 BMW 2002: Chamonix (Anakin ... as in Vader)

1973 BMW 3.0 cs: Malaga and Polaris (OWAM & TBD)

1963 Buick Riviera (Vernal)

1935 Alaskan Malamutes (year of AKC recognition)

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Steve scared me for a second by asking what manifold it was designed for ( I thought I did the spacing wrong for my car). The spacing is for my Cannon manifolds which has a center space of ~4.275" (~ because it should be in metric)

I have an email posted in my profile, but email me at bry2002bmw@gmail.com , I get less spam there.

Plugs were resin coated today, I will sand the resin tomorrow and re-coat if needed.

Bryan

red73

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73' 2002 "red"

66' 2 Door Cortina GT

http://mk1cortinasearch.blogspot.com/

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  • 3 weeks later...
  • 2 months later...
  • 1 month later...

Gotta love that AutoCad 3D! My company uses it to design our S/S and C/S drying hoppers for the plastics industry (from 10 lbs. up to 15,000 lbs. capacity).

Good luck on the intake project. Now if someone could come up with a replacement air cleaner for the tii...can you/are you willing?

Jim Gerock

 

Riviera 69 2002 built 5/30/69 "Oscar"

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  • 4 months later...

Well.....don't know if anyone sees projects this far down. I have some updates. I put this project on the back burners as I decided getting the car running again was more important than making an airbox for a nonrunning car!

So, now that the car is running, and my wedding is over, I have some time to devote to the project. I am almost to the point on one half of the molds where I can try and make a part, and the other mold is halfway in the lay-up.

I found I designed the molds with a little draft lock, so each half has to be split in half to pull apart, fun stuff.

So, I have some updated pictures. Mold doesn't look great in the picture, but its just sand through you see.

I will be looking for one person with DCOE's and a tii brake booster to test it out and see if it fits. Probably will sell for less as I'm not sure if it will fit right off the bat, or if some cutting is needed. I have a regular brake booster, so I can test that myself. Cost for the intial tii tester guy would be $200

For any others interested if they do come out looking ok. I have about 4 different weaves of carbon, and one of yellow Kevlar.

I'm probably a few weeks off of having the second half finished, and maybe a week away from producing the first part out of the other half of the mold.

Bryan

red73

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73' 2002 "red"

66' 2 Door Cortina GT

http://mk1cortinasearch.blogspot.com/

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Well.....don't know if anyone sees projects this far down. I have some updates. I put this project on the back burners as I decided getting the car running again was more important than making an airbox for a nonrunning car!

So, now that the car is running, and my wedding is over, I have some time to devote to the project. I am almost to the point on one half of the molds where I can try and make a part, and the other mold is halfway in the lay-up.

I found I designed the molds with a little draft lock, so each half has to be split in half to pull apart, fun stuff.

So, I have some updated pictures. Mold doesn't look great in the picture, but its just sand through you see.

I will be looking for one person with DCOE's and a tii brake booster to test it out and see if it fits. Probably will sell for less as I'm not sure if it will fit right off the bat, or if some cutting is needed. I have a regular brake booster, so I can test that myself. Cost for the intial tii tester guy would be $200

For any others interested if they do come out looking ok. I have about 4 different weaves of carbon, and one of yellow Kevlar.

I'm probably a few weeks off of having the second half finished, and maybe a week away from producing the first part out of the other half of the mold.

Bryan

red73

Bryan where do you live- nevermind looks like north Cali?

My car is getting the tii booster installed this week. I currently have twin webers 40dcoe. I'm up for it if you need a tester. I live in southern cali.

Here is my dcoe setup minus the tii booster that should be done this week. I also removed the battery to the trunk for an even more clearance.

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mthreez@gmail.com let me know.

Hamada

70Bristol02 E36M3 E34535im

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If Hamada stays interested, he will be the tii booster guinea pig.

I hope to have a completed box to test on my car within a month, and hopefully will be able to make some more after that. I also have another guy in line for the 1st non-test airbox.

If all goes well, I would like to sell between $400-$500, price depending on interest and how well I actually make them.

Once the molds are complete and I iron out the details on the airbox's, I am going to try and make a connector from the airbox opening to the front of the car to funnel in cold air. I would like to make this out of carbon, with possibly a 3-4" inlet bell.

Thanks,

Bryan

red73

73' 2002 "red"

66' 2 Door Cortina GT

http://mk1cortinasearch.blogspot.com/

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  • 1 month later...

Well, I have been going slower than planned, busy at work = not as much at home in the garage! I also haven't wanted to post until my infusion set-up passed a test......which took a while. First shot in the mould didn't go so well, so I pulled the bag and wet laid it to save the part..though it ended up with some air.

In the meantime, I figure out how i'll join them, and I wet laid fiberglass for the runners just to get stuff done.

Figured out my resin was too thick, so I thinned it down and it infused great tonight (though I did it on a flat glass panel to save time and effort). So, I should bounce back, in the meantime I need to finish up the other half of the mold. Here are some pics.

Pricing if they ever come out.....don't take my word from before, they are taking a lot more effort than I had planned.

-Bryan

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73' 2002 "red"

66' 2 Door Cortina GT

http://mk1cortinasearch.blogspot.com/

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Bryan,

That looks like it will be a very nice product at the end. I am still on stand by when you are ready. I am currently running with no filters so it looks like I might have to get something for protection until you are done.

I pulled out one of my horns to take a look yesterday. Looks like 2 inches long. I thought it was the long one that inserts inside the carb, but it turned out like this and there is a big O ring between this and the carb body if that makes sense. Let me know if you need any more info from me.

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Good luck and keep us posted. Do you think its another month probably? no rush just asking.

Hamada

70Bristol02 E36M3 E34535im

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Hamada, I am releasing the one mold, and getting the other almost there. I should hopefully have time to infuse a part out of each mold this weekend, how they turn out i'll have to see.

As for when I have a completed one for you....maybe a month (hopefully a conservative guess)

The box is designed to mount to that bolt pattern your airhorn has, so it will be good for that.

I'll keep you/everyone posted.

-Bryan

73' 2002 "red"

66' 2 Door Cortina GT

http://mk1cortinasearch.blogspot.com/

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