my latest project

My buddys got a 2j lexus is300 thats worked on by titan motorsports. Hes got about 1100 hp and his other car which is a ek hatch with a boosted k20 pushing 700 hp and also has a 550 hp datsun 500 lol, another friend has 2 240s one with a 2j and one with a sr20. ALL of these are awesome but the is300 is a scary machine. He raced a twin turbo viper about a month ago with me in the car and it sounded like a airplane taking off. The verdict of the race was the IS by about 4-5 cars
 
1st pic: prepping the other side for gel coat, waxing it, cleaning the excess clay out from the cracks
2nd pic: sprayed it with gel coat and let it get tacky
3rd pic: had to repeat the process of laying down fiberglass matt then cloth with some resin in between each layer
4th pic: we had to let it bake in the oven for an hour and a half, then took it out and drilled the flange before popping them off from each other
5th pic: and there she is
 
1st pic: both sides of the mold without the plug
2nd pic: after we pulled the plug out more oven cure time for like an hour at about 180 degrees
3rd pic: i wetsanded with 2000, then did two steps of polishing on the inside of the mold
4th pic: starting to lay the carbon
5th pic: 4 layers of carbon, the outside will have a smaller weave than the inside.

now we have to bag it, vacuum pack it, and oven cure it for 3 hours. ill get some more pictures. should finish it up today.
 
very, very nice redboost10. Can't wait to see it installed....
 
Thank you Ryan, installing it is a whole different ball game. I made it a tight fit and as big as I possibly could have. I need it to align perfectly to the headlight and then worry about the turbo side of it later.

At least we were able to keep the plug once we popped it out of the mold so we can use that to help us mount it in since we will be needing to bore a 5.6 inch hole to fit over the turbo perfectly and tightly and dont want to guess and check with the carbon piece, haha.
 
thank you. i appreciate it. cant wait til its out of the oven and done
 
thank you harleyguy. i have did fiberglass work before. and making a cf part is just taking fiberglass one step further actually. you can see that i am in a shop doing all the work. the owner used to drive my grandfathers outlaw late modified dirt track race car and is a really good family friend.
 
redboost10 said:
thank you harleyguy. i have did fiberglass work before. and making a cf part is just taking fiberglass one step further actually. you can see that i am in a shop doing all the work. the owner used to drive my grandfathers outlaw late modified dirt track race car and is a really good family friend.
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Can't beat having to shop to work in .Seems like you come from a long line of friends and family that are into cars.
 
yes i do, haha. dad was into the whole circle dirt track stuff, which i agree is more fun than drag racing, but who wants to spend all that time making a car look so nice then go out there and just destroy it, but it is part of racing.

thats why i stick to drag racing, the car still looks good no matter how many times you go down the track, except this front wheel drive stuff tends to throw rubber all over the car including the hood and roof, haha.
 
1st pic: we bolted the two parts together once we got the carbon layed out in the molds, and put a releasing film on it that is breathable and will let the excess resin out, then wrapped it with this felt type material which serves to soak up the excess resin and so the resin does not stock to the acutal vacuum pack bag
2nd pic: all vacuum packed and ready to be baked
3rd pic: cooling down after the bake, you can see the excess resin (the black stuff) that got pulled out from the carbon and soaked up by the breather film
4th pic: there she is, actually glossier than we thought it was going to turn out
5th pic: you can see the two different types of cf weaves i used. i wanted the small stuff on the outside and the larger stuff on the inside. this is pre-peg which has the resin built into the carbon where as wet layup requires external resin to be added to it. the prepeg stuff is about 97 bucks/sqr meter.

this last pic is of the air duct not all the way trimmed and it weighs 8 oz. i still need to trim where it butts up against the headlight and obviously need to bore a whole where it will fit over the turbo compressor. i was amazed how smooth it was and how glossy it was. im going to try to pull a little more gloss out of it with some nano and a blue pad before mounting it in the car.

thanks for looking guys.
 
Thanks Ryan, definately a lot more work than I anticipated although I do not regret it at all.
 
thank you very much! My only complaint is the seem where you can tell it was two halves, but there was really no way around that. I still got the mold so I can make more, haha. I guess a mold is good for about 100 parts before it kinda just starts to decompose.
 
got it all mounted today. of course it was an all day thing, had to trim it, then fit it, then try to figure out how to mount it. going to put it on the scales and balance it tomorrow then going to the dyno next friday, cant wait! i will have some pics of it installed tomorrow.
 
redboost10 said:
got it all mounted today. of course it was an all day thing, had to trim it, then fit it, then try to figure out how to mount it. going to put it on the scales and balance it tomorrow then going to the dyno next friday, cant wait! i will have some pics of it installed tomorrow.
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Look forward to seeing those Dyno numbers:cheers:
 
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