Xtra Posted May 16, 2021 Author Report Share Posted May 16, 2021 (edited) Today was a very good day. I accomplished so much. I was able to get the draft angles set and the fit fine tuned. it is ready for a finish coat and to be transformed into a vacuum form mold. Edited May 16, 2021 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 16, 2021 Author Report Share Posted May 16, 2021 To test the fiberglass plug I shaped cardboard over it and hot glued it together to make a paper part. After spray painting I taped the replicate cardboard part into place on the air box, and tested it for fit. I then cut some foam core to size and cut a port for the snorkel, and taped that into place on the air box as well. Now I had all the parts in place to test fit it into the car. I did not want to build it first then find out there were problems with the fit better to fix paper parts than ABS ones. 3 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 16, 2021 Author Report Share Posted May 16, 2021 (edited) Now that all the parts were taped in place I needed to see if it would fit in the car. I decided to drill a hole for the sensor and temporally installed it as well for a full dress rehearsal. Here you can see just how tight a fit it is as the Air Box touches the fuse box ( I think it is fuse box) , but it fits. You can see the sensor hook up as well in this photo. The mandrel bent elbow reducers close up. Just because Edited May 16, 2021 by Xtra 2 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 16, 2021 Author Report Share Posted May 16, 2021 (edited) After I test fit everything and the sensor was installed I thought ... What the heck, take it for a drive. So that is exactly what I did. I started the car checked for warning lights and went for a short 5 mile drive.. The car seemed to quiet down some and run smoother . I did not try to set a new 0 to 60 record just drove it around . After the drive I pulled the intake and checked for any problems . The cardboard and painters tape is not very strong and if there was any thing hitting rubbing or over heating it would show quickly. Everything looked great so onward. I put a tag on the air box only for ID . I have no intention of putting a label on it when finished. Here are a couple photos of the V2 in Carbon Fiber and the V3 working together for the first time. Edited May 16, 2021 by Xtra 5 Quote Link to comment Share on other sites More sharing options...
MSCOSC Posted May 16, 2021 Report Share Posted May 16, 2021 Damn guy that looks incredible. I'm interested to see how you mate the snorkel to the box. Doesn't the OEM one snap into place? 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 16, 2021 Author Report Share Posted May 16, 2021 (edited) Thanks MSCOSC glad you like it. You are correct sir, the OEM snorkel does snap into the air box. It is my intention to use rubber top bulb edge gaskets. I posted a photo of the two different ones that I am considering. There is no chance of the snorkel getting out of place with the V3 because the fit is so tight it can't move that much.The main consideration is stopping any hot air from getting in. Edited May 16, 2021 by Xtra 1 Quote Link to comment Share on other sites More sharing options...
CrackedDSM Posted May 16, 2021 Report Share Posted May 16, 2021 (edited) Commenting so it updates me on posts. This looks incredible. This, combined with your V2 intake, and the UP intercooler would be super effective at controlling these insane engine bay temps. Question, have you thought of making your own snorkel too? Something to compliment the V2 intake and maybe even something that works with keeping the AGS shutters or at least only removing the drivers side top two shudders instead of the whole thing? I really do not want to sacrifice having quick heat in the winter, but would love the benefits of a snorkel. Edited May 16, 2021 by CrackedDSM 1 Quote Link to comment Share on other sites More sharing options...
MSCOSC Posted May 16, 2021 Report Share Posted May 16, 2021 2 hours ago, Xtra said: Thanks MSCOSC glad you like it.You are correct sir the OEM snorkel does snap into the air box. It is my intention to use rubber top bulb edge gaskets. I saw that photo I guess I just didn't realize the context. Have you considered making the lower box include the snorkel? or at least the part that feeds through that air inlet, I wonder if it could be integrated into one piece 1 Quote Link to comment Share on other sites More sharing options...
Perblue Posted May 16, 2021 Report Share Posted May 16, 2021 1 hour ago, MSCOSC said: Have you considered making the lower box include the snorkel? or at least the part that feeds through that air inlet, I wonder if it could be integrated into one piece He wouldn't be able to use vacuum forming then and costs would go up significantly I'm betting. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 16, 2021 Author Report Share Posted May 16, 2021 54 minutes ago, Perblue said: He wouldn't be able to use vacuum forming then and costs would go up significantly I'm betting. True that. The V3 is pushing the cost limit as it is, and I am struggling to keep the price down as much as possible. The costs are so high because I am buying so much off the shelf then modifying it. Who knows it may end up changing direction by going back and rethinking the first design in order to lower the COG (Cost of Goods ) 2 Quote Link to comment Share on other sites More sharing options...
hyperc32 Posted May 17, 2021 Report Share Posted May 17, 2021 I remember the easier days with my mustangs just removing the fender wall black plastic behind the airbox and running some a/c flex worked great... Dumb question of think of 3d printing it first? or just in general probably would keep the cost down? 2 Quote Link to comment Share on other sites More sharing options...
handfiler Posted May 17, 2021 Report Share Posted May 17, 2021 46 minutes ago, hyperc32 said: I remember the easier days with my mustangs just removing the fender wall black plastic behind the airbox and running some a/c flex worked great... Dumb question of think of 3d printing it first? or just in general probably would keep the cost down? I worked in product development and printed numerous prototype parts over the years. For the most part they are used to develop and test. Larger parts require costly printers and it takes a long time to print larger parts. 2 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 17, 2021 Author Report Share Posted May 17, 2021 (edited) Today I worked on the sensor mount. Unlike the elbow reducers that needed welding all the way around this part also needs welding, but just a spot or two to lock the parts together . It will be pop riveted into place with some RTV to seal things up . So much fabrication in this project. The sensor just slides into place and has an O-ring to hold and seal it. Two pop rivets mounts it to the air box. Edited May 17, 2021 by Xtra 2 Quote Link to comment Share on other sites More sharing options...
hyperc32 Posted May 17, 2021 Report Share Posted May 17, 2021 Sorry I got bored have you thought about doing the filter box with the snorkel connected to the top half and just use pins aka remove the 2 snorkel bolts when filter swap or service is needed.. either way good work 1 Quote Link to comment Share on other sites More sharing options...
MSCOSC Posted May 17, 2021 Report Share Posted May 17, 2021 You don't want the snorkel to attach to the top of the box, it feeds from the bottom in case water/ moisture gets in there 3 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 17, 2021 Author Report Share Posted May 17, 2021 (edited) Had a powwow with the plastic shop today about the new vacuum mold. Should start building the wood base later this week. Edited May 17, 2021 by Xtra 4 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted May 17, 2021 Report Share Posted May 17, 2021 16 minutes ago, Xtra said: Had a powwow with the plastic shop today about the new vacuum mold. Should start building the wood base later this week. Yissssss... Excellent. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 18, 2021 Author Report Share Posted May 18, 2021 1 hour ago, Duece McCracken said: Yissssss... Excellent. You said it. And I feel the same way !! Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 18, 2021 Author Report Share Posted May 18, 2021 On 5/1/2021 at 5:55 PM, MSCOSC said: Is the new box much wider than the factory one? I have a 94r battery in there which is the largest you can fit in the tray, there is a hole for the bracket and everything. I have checked for you and fitting the V3 in with that battery will be very close, and it does look possible. Unfortunately I cannot give you a clean yes or no for fit. I guess the only way is to test fit it. 1 1 Quote Link to comment Share on other sites More sharing options...
MSCOSC Posted May 18, 2021 Report Share Posted May 18, 2021 (edited) I'm OK with some trial and error if you are lol One way you can try to test is to slide your battery forward to the last available hold down point. Edited May 18, 2021 by MSCOSC 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 18, 2021 Author Report Share Posted May 18, 2021 10 minutes ago, MSCOSC said: One way you can try to test is to slide your battery forward to the last available hold down point. That is a good idea, and easy enough to do. I will update you on this matter at a later date. I am curious as well. 1 1 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted May 18, 2021 Report Share Posted May 18, 2021 11 hours ago, Xtra said: That is a good idea, and easy enough to do. I will update you on this matter at a later date. I am curious as well. Please do, I also run the larger battery. 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 22, 2021 Author Report Share Posted May 22, 2021 What if ? I was thinking ...What if the V3 was offered in real Carbon Fiber as an option. The real deal Carbon Fiber, not carbon fiber material as in the V2. I have no idea how much it would cost but it could be an option. What do you think? 1 Quote Link to comment Share on other sites More sharing options...
Duece McCracken Posted May 22, 2021 Report Share Posted May 22, 2021 31 minutes ago, Xtra said: What if ? I was thinking ...What if the V3 was offered in real Carbon Fiber as an option. The real deal Carbon Fiber, not carbon fiber material as in the V2. I have no idea how much it would cost but it could be an option. What do you think? Dude, you love emptying my bank account. You animal. If you offered it, I'd have to get it. So first dibs. Its going to add complexity, so maybe doing it half in CF, or something like that. IDK. Just tell me how much, so i can send the money. Lol 1 Quote Link to comment Share on other sites More sharing options...
Xtra Posted May 22, 2021 Author Report Share Posted May 22, 2021 54 minutes ago, Duece McCracken said: . Its going to add complexity, so maybe doing it half in CF, It would be only the top half, the part you see. The rest would remain the same. It would add more cost than complexity and this project is already pushing the cost limits as it is IMO. 2 Quote Link to comment Share on other sites More sharing options...
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