ImLivingOnTheEdge Posted February 6, 2021 Report Share Posted February 6, 2021 On 1/17/2021 at 9:40 PM, Xtra said: lildisco volunteered his time and energy to confirm for us that the intake does not fit 2019, 2020, or 2021 Edges. The mounting holes do not line up, the hood's rubber bump stops do not line up, and there is no way to modify it to fit. Ford made these changes starting in 2019. Thanks for the clarification of the issues. I hope some day you will be able to make a product for the newer models. Thanks for your time, I can see you are working hard for the community. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 9, 2021 Report Share Posted February 9, 2021 (edited) I would like to give props to Duece McCracken for the photos he sent me as they helped a lot, and answered questions for me about the 2015 intake fitment. Armed with this new info, I believe that there will be no more problems with the 2015s. Now work can begin. After a meeting with the plastic shop, I have a lot more to do than originally thought. This first cut I made is at the request of the shop to help release the intake from the mold. I will give updates as I progress . On a personal note, I am making a lot of nasty fiberglass dust, and once again I am not allowed in the house with my dusty clothing, and we don't have a mudroom to change in. LOL Edited February 9, 2021 by Xtra 3 1 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted February 9, 2021 Report Share Posted February 9, 2021 12 minutes ago, Xtra said: I would like to give props to Duece McCracken for the photos he sent me as they helped a lot, and answered questions for me about the 2015 intake fitment. Armed with this new info, I believe that there will be no more problems with the 2015s. Now work can now begin. After a meeting with the plastic shop, I have a lot more to do than originally thought. This first cut I made is at the request of the shop to help release the intake from the mold. I will give updates as I progress . On a personal note, I am making a lot of nasty fiberglass dust, and once again I am not allowed in the house with my dusty clothing, and we don't have a mudroom to change in. LOL Sounds like Tyvex suits are in your future, lol!! 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 9, 2021 Report Share Posted February 9, 2021 2 hours ago, Duece McCracken said: Sounds like Tyvex suits are in your future, lol!! Good idea , It could do double duty . Protecting me from the fiberglass dust and when I go out in public. Who need a mask when you have a full Tyvex suit ? 2 1 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted February 9, 2021 Report Share Posted February 9, 2021 1 hour ago, Xtra said: Good idea , It could do double duty . Protecting me from the fiberglass dust and when I go out in public. Who need a mask when you have a full Tyvex suit ? Sad thing, is that you probably won't be the only person in public, rocking one. Saw someone yesterday full PPE and booties. Boot condoms. Makes sense if immuno compromised, if not though, tinfoil hat. Sorry. 2 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 9, 2021 Report Share Posted February 9, 2021 (edited) That is amazing that you actually saw someone in head to toe PPE, I was joking about doing double duty and wearing that suit in public . Edited February 9, 2021 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 10, 2021 Report Share Posted February 10, 2021 (edited) Today I did some more work that the shop requested. In the first photo, you can see the straight sides of the hole. The shop requested that they be tapered some so that the intake would release easier from the mold. The second photo shows the completed mod. Little things like this help. Edited February 10, 2021 by Xtra 1 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 11, 2021 Report Share Posted February 11, 2021 (edited) I machined down all 12 of the hole marker screws as much as possible. Even though I had turned them down once before, and it was a huge improvement, the smaller the better. Because of all the contours, hand sanding is the way to go. I Swiss Cheesed one of the intakes to measure how much material was being removed from the mold. Edited February 11, 2021 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted February 11, 2021 Report Share Posted February 11, 2021 wait, say that again, "the smaller ..." 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 11, 2021 Report Share Posted February 11, 2021 (edited) Perhaps I should have said something like. The more minuscule the marker, the greater the precision. Edited February 12, 2021 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 12, 2021 Report Share Posted February 12, 2021 (edited) Had to go to the hardware store for more sandpaper today, and work continues. I have removed approximately .125 of an inch so far and will take it down some more to account for the thickness of the finish coat. The Swiss Cheese intake has proved to be very useful in keeping track of progress. Edited February 12, 2021 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 16, 2021 Report Share Posted February 16, 2021 (edited) Underneath the nice white finish coat, I discovered that some hairline cracks have formed in the mold. This proves that the mold will have a short life as I originally thought. I believe that it will survive long enough to complete all the orders and a few more beyond that, so no worries, but it is far from permanent. Edited February 16, 2021 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 16, 2021 Report Share Posted February 16, 2021 (edited) I have added 6 very small vacuum holes along the gasket line to help pull the material into critical areas of the intake. This should help with defining the gasket line and help the overall fit. Edited February 22, 2021 by Xtra 1 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 19, 2021 Report Share Posted February 19, 2021 (edited) I picked up an air hose coupler from Harbor Freight that allows me to have up to three air tools hooked up at one time. This is a real-time saver not having to swap tools back and forth constantly. Edited February 19, 2021 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 19, 2021 Report Share Posted February 19, 2021 (edited) I cut up the OEM sight shield to check the alignment of the marker screws. Edited February 19, 2021 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 19, 2021 Report Share Posted February 19, 2021 (edited) I moved the gasket line back .25 inch to match the work I had done on the upper part of the intake. A 1/4 inch may not sound like much but in this case, it is a lot. I hope that 1/4 inch is enough to accommodate any differences in hood alignment. I also had to fill in the old screw holes because of the new smaller heads on the marker screws. I put in long screws and glassed-in around them, then I will pull the screws when the glass hardens and sand flush. Edited February 19, 2021 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted February 19, 2021 Report Share Posted February 19, 2021 Sweet. Loving the updates. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 20, 2021 Report Share Posted February 20, 2021 (edited) Here is the same hole as in the above photo after patching and rough sanding. Edited February 20, 2021 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
NinjaToes Posted February 20, 2021 Report Share Posted February 20, 2021 Awesome work, possibly interested when the mold for v2 is ready depending how much shipping to Canada would cost. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 21, 2021 Report Share Posted February 21, 2021 (edited) Checking the hood's rubber bumper hole alignment. I cut up the OEM sight shield some more to make sure of the alignment. As far as I can tell it is spot on even though the mold holes are a bit smaller than the OEM holes. There are different sizes of the rubber bumpers and they are much smaller on the 2015 Edge than on the 2016. When a CAI was placed on a 2015 Edge the rubber bumpers did not fill up the holes as nice as on my 2016 Sport and did not center up, even though they still fit in the holes. Not sure how to fix that. Edited February 21, 2021 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 21, 2021 Report Share Posted February 21, 2021 (edited) 2015 VS 2016 This intake is on a 2015 and has a wrap. It is not pushed down over the bumpers or seated correctly with clips. The bumpers do move a little so it does fit, they are just off-center. When the intake is pushed over the bumpers it is not as bad as in this photo. The offset is divided between the two holes and not just the one as in the photo. These are the only photos I have to work with. Below is my CF intake installed on my 2016 Sport. You can see the different size of the bumpers compared to the 2015, and how they are a good fit. You do not just drop the intake into place, it has to be wiggled over the rubber bumpers as it is a tight fit to keep as much engine bay hot air out as possible. I am not sure how to correct this discrepancy between the 2015 and the 2016 Edge. Edited February 21, 2021 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 21, 2021 Report Share Posted February 21, 2021 (edited) I wish to remind everyone that this is a one man backyard project. The engine compartment was not scanned. And that scan given to another company to develop the intake on a cad computer Then another engineer to take the cad drawings and make 5 axis mill CNC programs . Then actually CNC a pressure injection mold that is accurate to . 001 inch.. like a factory part. To develop the intake to that level tens of thousands of dollars would be needed. This is a low volume custom part that does not justify such a large investment. It is accurate enough to fit, look good, and work as designed for a lucky few enthusiasts. A one man project that is not accurate to .01 inch ( closer to .1 inch ) and is not Ford factory perfect. If you have a 2015 with the small rubber bumpers and you want them to be perfectly centered then I am afraid I cannot fix that and keep the tight fit on the 2016,17 and 18s. Edited February 21, 2021 by Xtra 3 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted February 21, 2021 Report Share Posted February 21, 2021 53 minutes ago, Xtra said: I wish to remind everyone that this is a one man backyard project. The engine compartment was not scanned. And that scan given to another company to develop the intake on a cad computer Then another engineer to take the cad drawings and make 5 axis mill CNC programs . Then actually CNC a pressure injection mold that is accurate to . 001 inch.. like a factory part. To develop the intake to that level tens of thousands of dollars would be needed. This is a low volume custom part that does not justify such a large investment. It is accurate enough to fit, look good, and work as designed for a lucky few enthusiasts. A one man project that is not accurate to .01 inch and is not Ford factory perfect. If you have a 2015 with the small rubber bumpers and you want them to be perfectly centered then I am afraid I cannot fix that and keep the tight fit on the 2016,17 and 18s. No worries, I'm fine with it. 1 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted February 21, 2021 Report Share Posted February 21, 2021 many many small changes that Ford does. even their original designs are obviously not perfect. what you have achieved is a labor of love. this might wind up with more hours in it that it would take to bore, hone, and stroke an engine lol. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted February 21, 2021 Report Share Posted February 21, 2021 6 hours ago, WWWPerfA_ZN0W said: . this might wind up with more hours in it that it would take to bore, hone, and stroke an engine lol. It has gone way beyond that. I cannot even begin to count the hours. It is in the hundreds. I have to rebuild the entire wood part next. The shop has requested that it should be narrowed down and shorter. Apparently when using a 2x4 ft sheet of material there’s just barely enough to clamp to making it difficult to work with. Having the large sheets cut to 2x4 ft gives 4 intakes per sheet. So rather than only getting 3 intakes from a sheet and the cost per unit goes up , I must rebuild the wood base . 1 Quote Link to comment Share on other sites More sharing options...
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