Well, lately i've been trying to find a way to replace the stock TPI air box. I'm also not using the MAF (SD). I think i came up with a good idea..... make a crossover pipe out of fiberglass. It has to be extremely thin and wide to make the CFM numbers... the stock C5 bridge didn't work....close...but no. Vortex makes a system that replaces it...but i don't need the whole system... and i'm not paying $300 just to use the crossover pipe... So i'm gonna try this fiberglass idea..and clean it up and paint it.... i'll post some updates.

 

Do you mean the air filter box or the plenum?

 

"replace the stock TPI air box" ....hhhhm.... the air box. I don't think that fiberglass would work well for a intake manifold/plenum. :lolg:

 

Plastic works well for the LS1/6.

 

I know they are. I doubt anyone could make a intake manifold though.. IM TRYING TO MAKE AN AIR BOX FOR THE TPI'S. b/c theres not much room to run a pipe across the top of the radiator. so it has to be wide and thin to let the hood close and flow enough air.

 

Maybe I can give you an idea?

I am making an air box myself too. I have a mock up built and I just need to build it out of glass now. I am using a traffic cone for a cross over because it will be way bigger for my needs. I am just looking for a way to build a wire outer structure so it will never collapse.

I have worked with fiberglass a bit, and I think you should get a traffic cone, cut it too size. put some pieces of cardboard into it so it keeps it long oval shape across the top of it, and put fiberglass over it.

this way when you are finished, you can remove the cardboard and peel the cone away from the glass, which should also give you a smooth flat surface inside the glass pipe.

If you are worried about the cone sticking to the glass, put a couple coats of wax on it, or WD 40. glass does not stick to these.

if you want to push down on the outside of it, you can used wax paper. Fiberglass will not stick to it. I dont think it will stick to foil, or saran wrap either.
Last time I built a mold with duct tape and the glass peeled right off the duct tape too.

 

aright, now we're talking. That's not a bad idea... Except... on the front of the radiator side... i'll have a HUGE wide open gap....that need to go to 3" like on the other side it would. Maybe i'll used 2 traffic cones. Thanks for the input. Where do you get some decent fiberglass for this kind of stuff?? AutoZone or a Boat marina store like West Marine??? thanks
-Jason

 

I have been just getting stuff from home depot.
There are two types of fiberglass clotch, one is the cloth, the other is the mat.

I think that mat is used for structural strength, it is also a PITA to work with. it comes apart pretty easy. I think it would work easy on a flat surface, but on anything you are shaping it too, it is a mess.

None if this stuff is real fun. It stinks bad, so do it outside, like well out of the garage. It is sticky, it wants to fall apart while you have the resin on it. I tried stapeling the cloth to my cardboard mold on one project, it seems to strech out when you put the resin on it, so that did not work, I had air bubbles once it dried.

The mat falls apart the most. it is just fibers layed together, it is not actually woven like the cloth is.

I use a junk paint brush to apply the resin, I use a punch the bristles into the fiberglass motion to get it in, you dont really brush it in, you force it in. I also used a bondo spreader type of thing to even it out. If you have Mat on there, it will be pulled along with it.

When you do this, wear nasty clothes you dont care about, some rubber gloves as it burns the skin a little and is a PITA to get off.
Make sure everything that touches the fiberglass can be thrown away, like the container you mix the 2 resin parts toegther in, and the brush, etc.

You are going to need some kick butt scissors too. The fiberglass will not cut easily unless you have some really good scissors.

Thats about all the advise I can think of for now.
You might want to play with it a little before you build the intake to get a feel for what it does.

Did you already build your air box?

 

This is exactly why I built my air cone duct before the box. So I could make my box fit the huge side of the cone. I think it will end up being something like an 11" opening. :lol:

{edit}
Just wanted to add one more thing. I read this on another web page and it is pretty true. There is no strength in the resin. the strength is in the cloth. The resin only bonds the layer of cloth together.

If you want to try something, I use junk tupperware containers to mix my resin, one I am done I, it dries in there, you can flex the tupperware and watch the resin crack and pop out. So if you are working on it and think some extra resin will help build up some strength in an area, think what will happen if it is hit or twisted. Use more fiberglass instead





[Modified by bill mcdonald, 12:28 PM 6/2/2003]

 

actually, i'm running a KN wedge filter like the C5 kits have...but i'm putting the filter itself right behind the front license plate. I cut 2 holes in the plate, so it looks like a 80's WS6 (at least to my friends..lol) and i'm running 3" mandrel piping through the bumper and up towards the radiator....but getting over it is the PITA. SO i guess i'm making a C4 air bridge like the C5's. (i tried the C5 bridge...close but no) thanks for the help... i'm sure this will work.... it has to. no option.
-Jason

 

After reading the posts,wonder if it would be easier to make a plaster or latex mold of what you want,after it cures and shaped to size,spray a release agent over it,then apply the fiberglass and matting to it,let it cure then take the new part off the mold??Sounds easy but unsure about the idea or if the materials would be more expensive in the long run.Still,the idea to mold and make your own air box/pipes and etc at home is pretty appealing to me.
Any thoughts on that?
:)

 

I've never worked with fiberglass, and never ever worked with plaster latex etc. I'm sure i'll get the hang of the fiberglass. I just wish GM had given us more room to make an intake. this is crazy. :rant: :cuss

 

I was looking at aci's web site and theres a link to show how they make their fiberglass bumpers and molds.Looks a bit more complexed than it seems eh?Just thought id post this for fun.Check it out here: http://www.acivette.com/index2.html

If the link takes you to intro page,click on "Tour ACI" then on the next page scroll to "Manufacturing" and the pics are on there.
I dont think Id be able to do this kind of work at home. :lol:
:crazy:


[Modified by Bill's86Coupe, 8:15 PM 6/2/2003]

 

Me and my dad made a fiberglass cab corner when we did the body work on my 67 Chevt truck. Was the only part that didn't rust out that winter :mad :mad :mad

GL with the air intake. :smash:

 

http://www.z06vette.com/forums/showt...threadid=38362

here is another link ro someone making some brake ducts.

I used cardboard to build my air box, I cut the pieces out then hot glued them together so I could pull it apart etc... Then I slammed it under the hood to see where it needed to be trimmed. I am still working on it at this point. when I get a good fit (I will probably have some rubbing) I will glass it and be done. I am building it in 2 halves to I can build up a structure for the air filter to sit on.

Another ides I thought of after looking at that page for the cross over tube, you could find some of that big green blocks of foam, cut it to shape, wrap it in duct tape and put your glass over that.