RCSB C1500 Full Protouring Chassis Build, Twin Turbo LS Swap

Got a good bit more work done of the Carbon Fiber work. The mold for the carbon fiber valve covers is done. I used the following

Partall #2 Wax for Plug Prep
Partall PVA film #10 for Release agent
Composite Envisions Polyester tooling Gel Coat (Orange)
Composite Envisions Polyester Tooling Resin
2 Layers of Surface Veil
1 Layer of 6oz Woven E Glass
2 Layers of 6oz CSM
3 Layers of 14oz CSM

It turned out great with the exception of the fillet radii. The clay i used is too stiff to form nicely. Ive since ordered Filleting Wax from freeman, so that should really improve the cosmetics of the next mold edge.













Video summarizing the process can be found here:

Well.. the first one came out perfect... and I screwed it up.
Ended up mixing up the hardeners, and this one got done with High Temp Epoxy, but Standard temp hardener.

Oops.

Expensive wall hanger/practice piece

Video explaining the process is here:

Got some more progress done.

Made flexible intercooler mounts that allow the intercooler to move a bit
Got turbo's chassis mounted
CFD checked my design. Its optimized around distribution rather than pressure drop. This is more effective in lowering Compressor work in my cycle calculations.
Got intercooler bottom half welded up.
Got HD clamps welded up to the compressor discharge.

Also I got two more valve covers made with the CORRECT hardener... so these will be about to be post cured in my curing oven im going to build.

Video with all the deets is here:

Continued

loudandproud said:

Got some more progress done.

Made flexible intercooler mounts that allow the intercooler to move a bit
Got turbo's chassis mounted
CFD checked my design. Its optimized around distribution rather than pressure drop. This is more effective in lowering Compressor work in my cycle calculations.
Got intercooler bottom half welded up.
Got HD clamps welded up to the compressor discharge.

Also I got two more valve covers made with the CORRECT hardener... so these will be about to be post cured in my curing oven im going to build.

Video with all the deets is here:

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Somebody has welded before

Started working on some carbon fiber brake ducts. Worked through some trial and error making some.

The winning combination used Soller Composites 12k Twill Sleeves and their shrink wrap method. I used the same 450F Tooling resin from RDR for the tubes to make sure they can handle the indirect heat exposure of the brakes. The brake shrouds will have temp sensors monitoring the rotor temps and ducted Detmar fans to cool. The shrouds shouldnt get too hot even on shut down thanks to the temp sensors and controller. Ill control the fans based on what pads im running and run a PID control with the fan motors. On shut down the fan blowers will be on a time delay shut down to ensure that the brakes dont overheat the shrouds.


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Slowly getting this thing tricked out bit by bit...

Got the passenger side brake duct finished.
They will get Detmar 4" Nascar takeoff blower fans piped inline. The ducts are made for an inboard feed rotor, which my eventual two piece rotors will be, hence why it looks goofy the way theyre ducted.

continued

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