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gbrettin 04-12-2020 07:23 AM

From IG @gbrettin

This Fast Intentions exhaust is going back on my 370z. guess we'll know what a V8 sounds like through Fast Intentions exhaust. But first i'm going to polish it out.

Custom pan being made for the Z, way out of my swim lane. Letting the pros knock that one out.

Time to knock my pin on hood mould out! (I like the British spelling for mould). Composite Envisions still cranking out shipments, thank you. Their site says they are taking all the Covid-19 precautions while working and more importantly, I trust them they are. Their support staff has been great to deal with when ever I have questions or need assistance! Highly recommend!

Bolts came in for the flywheel. Tightened them down to spec, 85ft/lb, and managed to punch my head with an 85ft/lb thump...

The "big" 4L80e is in the Z. It fits no problem . TBH, stock 7AT is larger and blows up at 450hp. This one can hold about 1500.

Final layer for pin on hood mould. My safety gear is for fighting all the Covids of 19. * Edit * ... It needs two more layers...

Last leg of the night and done. Made room for turbo piping. ... I'm beat.

Took off the harmonic balancer, put it on, pulled it off, put it on --- then got my timing marks set up on the harmonic balancer and my @motionraceworks timing pointer. Why didn't I do it the first time I put it on? Squirrel... Moving on... I notched out an area for turbo plumbing. Welds will go where the missing pinch welds are. As far as the pin on hood goes, I need to put two more layers of fiberglass on... Heh. Thanks for all the help everyone!

Two 3" boost actuated dumps came in. At 5/6 lbs of boost my car will bypass the Fast Intentions 2.5" exhaust and switch automatically to open dumps near the turbo. This is the best of both worlds, quiet exhaust when cruising and open hells gates when I'm into the gas.

----------------------------------------

Picture heavy since I was working on my car and hood the last few days.

F.I. Exhaust and Loud Valve
https://zcmrga.dm.files.1drv.com/y4m...&cropmode=none
https://zclldg.dm.files.1drv.com/y4m...&cropmode=none

Custom Pan
https://zsmsga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmrga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmuga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmtga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmwga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmvga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmyga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmxga.dm.files.1drv.com/y4m...&cropmode=none
https://zsmaga.dm.files.1drv.com/y4m...&cropmode=none

Composite Supplies!
https://bslodg.dm.files.1drv.com/y4m...&cropmode=none
https://bslrdg.dm.files.1drv.com/y4m...&cropmode=none
https://bslpdg.dm.files.1drv.com/y4m...&cropmode=none
https://bslidg.dm.files.1drv.com/y4m...&cropmode=none
https://bslmdg.dm.files.1drv.com/y4m...&cropmode=none

Transmission Installation
https://bslldg.dm.files.1drv.com/y4m...&cropmode=none
https://zclrdg.dm.files.1drv.com/y4m...&cropmode=none
https://zclqdg.dm.files.1drv.com/y4m...&cropmode=none
https://zyljdg.dm.files.1drv.com/y4m...&cropmode=none
https://zylidg.dm.files.1drv.com/y4m...&cropmode=none
https://zylldg.dm.files.1drv.com/y4m...&cropmode=none
https://zylkdg.dm.files.1drv.com/y4m...&cropmode=none
https://zylndg.dm.files.1drv.com/y4m...&cropmode=none
https://zylmdg.dm.files.1drv.com/y4m...&cropmode=none
https://zylpdg.dm.files.1drv.com/y4m...&cropmode=none

Mould reinforcement
https://zylodg.dm.files.1drv.com/y4m...&cropmode=none
https://ziljdg.dm.files.1drv.com/y4m...&cropmode=none
https://zilldg.dm.files.1drv.com/y4m...&cropmode=none
https://zilkdg.dm.files.1drv.com/y4m...&cropmode=none
https://zilndg.dm.files.1drv.com/y4m...&cropmode=none
https://zilmdg.dm.files.1drv.com/y4m...&cropmode=none

Making room for turbo piping
https://zilpdg.dm.files.1drv.com/y4m...&cropmode=none

Caught my hand inbetween car frame and ratchet. Impact facilitated the hand crushing.
https://zilodg.dm.files.1drv.com/y4m...&cropmode=none
https://zilrdg.dm.files.1drv.com/y4m...&cropmode=none
https://zilqdg.dm.files.1drv.com/y4m...&cropmode=none
https://asljdg.dm.files.1drv.com/y4m...&cropmode=none
https://aslodg.dm.files.1drv.com/y4m...&cropmode=none
https://aslldg.dm.files.1drv.com/y4m...&cropmode=none
https://aslndg.dm.files.1drv.com/y4m...&cropmode=none
https://aslmdg.dm.files.1drv.com/y4m...&cropmode=none
https://aslpdg.dm.files.1drv.com/y4m...&cropmode=none
https://acljdg.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 04-14-2020 09:51 AM

From IG @gbrettin
Good news! Popped my hood from the mould and it's going to be useable! I have a few problem areas but I honestly anticipated A LOT more. Everything can be repaired and I have the tools. Next mould will be a lot easier due to some of the pain points on this one.

Carved out pin holes and detects with the grinder. Now I can build it back up. ... A different night.

--------------------

Extra info:

The PVA that was used on the hood created a crazy static charge. When I popped the hood from the mould with my buddy, we got shocked... It felt like we got hit by 110. Actually, I should have gotten pictures of the PVA coming off because it was awesome to see it pull out of the mould.

Breaking the hood from the mould was pretty wild. Dave put a couple plastic pry tools in a corner while I went beast mode breaking the hood free from. when it released there was a huge * POP *. Not gonna lie, I was pumped off some anxiety when it released. I was expecting it to be WAY worse. I sent the same pictures to a guy I know that does carbon fiber and he wasn't put off from any of the pictures. He was like, "Yeah, that can be fixed in a few days no problem." Only issue I see is doing one corner. everything else can be blocked easy(ish). The edge of the mould will not be part of the hood. I just need to get it filled.

Cut extra flange off
https://bsnqaq.dm.files.1drv.com/y4m...&cropmode=none
https://bsnpaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcnhaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcniaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcnkaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcnmaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcnlaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcnoaq.dm.files.1drv.com/y4m...&cropmode=none
https://bcnpaq.dm.files.1drv.com/y4m...&cropmode=none
https://zslkdg.dm.files.1drv.com/y4m...&cropmode=none
https://zslndg.dm.files.1drv.com/y4m...&cropmode=none
https://zslmdg.dm.files.1drv.com/y4m...&cropmode=none
https://zslpdg.dm.files.1drv.com/y4m...&cropmode=none
https://zslodg.dm.files.1drv.com/y4m...&cropmode=none

madwi 04-14-2020 02:23 PM

This is a really great thread.

Hotrodz 04-14-2020 05:00 PM

Quote:

Originally Posted by madwi (Post 3924879)
This is a really great thread.

^^^Agreed!

Sent from my SM-G965U using Tapatalk

gbrettin 04-15-2020 09:50 AM

IG @gbrettin:
The GOAT, @cjmotorsportsinc ,of fuel systems anodized my FPR. It looks awesome and I like how the Aeromotive is shadowed. ��

Man, this is going to be a lot of sanding.

-------------------------

MAN, you have no idea how much that means to me that a few of you guys enjoy going through some of these pictures. They really are a PITA sometimes to get. Also, it’s a real kick in the nuts posting some of the fails that go hand and hand with being new at doing this. If seeing these pictures helps someone somehow then it's worth it. Having a cataloged path of completion is pretty cool to have on a build is pretty rad in the long run.

IG comments summed it up what is happening well. I see lots of sanding in my future. The good news is that I have some nice sanding blocks and can chew through the high spots easy. Worst case scenario for this mold is this: I don't do a beauty layer of carbon fiber later. I can do two layers of CF with the mould and then do a wet lay up over the vacuum infused part. I don't anticipate going that route but it's nice to have a plan B.

Maybe I should do a better job explaining what is happening in pictures... The perimeter of the mould had some dry fiberglass issues. I cut all that out previously with trusty death wheel. I filled in the pockets with fiberglass. The high up perimeter isn't terrible important because I can sand that back to the flange no issue. I just needed something to sand back for a transition from the mould.

The inner part of the mould was filled with tooling gel with a mixture of wax. The wax is needed so that the tooling gel can cure properly. Tooling gel is typically sealed off by the fiber glassing process and cures that way. Normally, people make a mould that doesn't suck so bad and can pop off a perfect mould. My inexperience shows you the long road.... yay...

Also, Charles/Phunk anodized my FPR. Me being me, I marred it up within a few minutes putting it on with a big *** crescent wrench.

https://ainlaq.dm.files.1drv.com/y4m...&cropmode=none
https://ainnaq.dm.files.1drv.com/y4m...&cropmode=none
https://aynmaq.dm.files.1drv.com/y4m...&cropmode=none
https://aynoaq.dm.files.1drv.com/y4m...&cropmode=none
https://aynlaq.dm.files.1drv.com/y4m...&cropmode=none
https://aynnaq.dm.files.1drv.com/y4m...&cropmode=none
https://aynqaq.dm.files.1drv.com/y4m...&cropmode=none
https://aynpaq.dm.files.1drv.com/y4m...&cropmode=none
https://ainiaq.dm.files.1drv.com/y4m...&cropmode=none
https://ainhaq.dm.files.1drv.com/y4m...&cropmode=none
https://ainkaq.dm.files.1drv.com/y4m...&cropmode=none
https://ainjaq.dm.files.1drv.com/y4m...&cropmode=none

Rusty 04-15-2020 11:04 AM

I really do enjoy reading on what you are doing. :tup: Brings back nightmares of me doing some of the this. Best of luck to you with this project. :tup:

gbrettin 04-16-2020 11:27 AM

Started in on sanding the hood and let me tell you this, tooling gel gets hard AF! I started off with my 400grit sanding block and quickly went down to 60. You are looking at 3.5hrs of sanding. There's a LOT more sanding to go as well. I'm going to try doing some surgical hits with the death wheel tonight to reduce arm fatigue. I will also need to do a skim coat in almost all the areas and do another knockdown with fine grit. Eventually I will make it up to 1500 wet sanding. Last step is polishing, distant horizon at this rate. Like I said, this mould is workable and will take a lot of work.

If anyone is curious about the weight of the mould, the weight is around 75 -100lbs. lol

This Saturday I'm going to start in on making the cowl. I'll need to come up with a bone structure made out of wood. It will look similar to the cardboard structure I made previously but have widths as well as height. The wooden structure will give me stop points for my tungsten carbide sanding block.

Cardboard will sit around the wood structure and on top while it is sitting on the hood. This will allow the foam to take the shape of the hood, encapsulate the wood structure and then rise up to the top of the cardboard. Relief holes will be cut into the top of the cardboard so that the expanding foam doesn't bust through like the Kool-aid man.

The cowl needs to come in close to perfection. I'm glad I started with my hood and have worked through all the repairs. I've seen with my own eyes and connected the dots why certain aspects went well and other items turned out like garbage.

Most important of all, I've always wanted to make a meaningful composite part stretching myself into new areas. Honestly, I can't suggest starting on a hood. Personally, I go head first into projects so it is what it is; however, I think that's been well f*cking established how far I'll go off the beaten path.

Good thing I have the hood because I am currently waiting on my order of wastegates, blow off valves, couplers and v-bands. The wastegates, BOV and couplers are all VSRacing. VSRacing recently had a design change and look REALLY nice. The shop bought a few for a twin turbo sandrail and was able to inspect them before I ordered. Vband clamps... That has got to be one of the biggest kicks to the balls. Ordering a handful of clamps was a rude awakening.

Guess my post is a little bit wordy today yet needed. Hopefully you can see the same path forward as I'm seeing.

https://acnkaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnjaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnmaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnlaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnoaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnnaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnqaq.dm.files.1drv.com/y4m...&cropmode=none
https://acnpaq.dm.files.1drv.com/y4m...&cropmode=none

madwi 04-16-2020 11:59 AM

Quote:

Originally Posted by gbrettin (Post 3925702)
Started in on sanding the hood and let me tell you this, tooling gel gets hard AF! I started off with my 400grit sanding block and quickly went down to 60. You are looking at 3.5hrs of sanding. There's a LOT more sanding to go as well. I'm going to try doing some surgical hits with the death wheel tonight to reduce arm fatigue. I will also need to do a skim coat in almost all the areas and do another knockdown with fine grit. Eventually I will make it up to 1500 wet sanding. Last step is polishing, distant horizon at this rate. Like I said, this mould is workable and will take a lot of work.



When you get good at sanding try your hand at finishing a plastic injection mold for clear plastic part like a headlight. :ugh2: I never had the patience to sit there but the guys would sand with 220 and work up to a finish with Charmin toilet paper, and it had to be charmin. :eekdance:

gbrettin 04-16-2020 12:26 PM

Quote:

Originally Posted by madwi (Post 3925706)
When you get good at sanding try your hand at finishing a plastic injection mold for clear plastic part like a headlight. :ugh2: I never had the patience to sit there but the guys would sand with 220 and work up to a finish with Charmin toilet paper, and it had to be charmin. :eekdance:

I have a buddy that polished metal die sets for injection moulding. He said that the metal had to be absolutely mirror finish perfect and would spend weeks sanding to absurd high number using diamond paper. THAT would be terrible. He said that he would find flaws for some reason or another late in the process and need to kick the part back to milling. That meant starting over. :owned:

JLarson 04-16-2020 12:39 PM

Less text, more boost noises!!

Looking good man. Cool to read about a different kind of fab project than normal.

madwi 04-16-2020 01:02 PM

Quote:

Originally Posted by gbrettin (Post 3925709)
I have a buddy that polished metal die sets for injection moulding. He said that the metal had to be absolutely mirror finish perfect and would spend weeks sanding to absurd high number using diamond paper. THAT would be terrible. He said that he would find flaws for some reason or another late in the process and need to kick the part back to milling. That meant starting over. :owned:

Thats exactly it what im talking about, final polish was the tp. :tup: I could never do it, about an hour in and I said f this and went back to my machine. :icon17: Made me appreciate them that much more and always tried to get the best machined finish to start with to save time. Ran a few extra cycles in the EDM machines crisping up the sharp corners and blending in transitions.
We made the molds for inifinty, honda and others. If you ever notice the seatbelt latch covers in a viper; I made the electrodes and burned the snake's face into the mold. :tup:

Your mold looks awesome and that cowl doesnt seem like its gonna be fun to mess with.

gbrettin 04-17-2020 12:07 PM

Quote:

Originally Posted by madwi (Post 3925726)
Thats exactly it what im talking about, final polish was the tp. :tup: I could never do it, about an hour in and I said f this and went back to my machine. :icon17: Made me appreciate them that much more and always tried to get the best machined finish to start with to save time. Ran a few extra cycles in the EDM machines crisping up the sharp corners and blending in transitions.
We made the molds for inifinty, honda and others. If you ever notice the seatbelt latch covers in a viper; I made the electrodes and burned the snake's face into the mold. :tup:

Your mold looks awesome and that cowl doesnt seem like its gonna be fun to mess with.

The cowl will have its own challenges of getting the left and right side mirrored, but I know I can nail the gel coat process on it. That will cut 90% of the repair work out.

I'm really considering moulding some vents into the cowl as well, so that engine bay air pressure can get out too.

On my hood, I really need a small duckbill to divert air up over the windscreen which would take care of a high pressure area that builds up at the center base. I forgot where I saw that particular 3d rendering of pressure zones on this site. The duckbill/diverter really should have been baked into the hood mould but I guess that can be a challenge for a different day. There are too many spinning plates as is.

madwi 04-17-2020 12:11 PM

You are making good progress, keep it up and moving forward. Cant wait to see how it goes as this is no small undertaking.

gbrettin 04-20-2020 10:36 AM

Not a whole lot to say other than getting a perfect surface is a PITA. I was doing this by hand and then realized there are tools for this type of job... I purchased the best orbital sander I could get my hands on and haven't looked back.

The thermal process that happens after 30min or so is pretty wild in the tooling gel. I took too much time applying the first skim coat and the tooling gel melted my plastic cup.

I suspect there will be one more knock down after the last skim coat mould is really looking good now.


First complete knock down and corner rebuild:
https://zynqaq.dm.files.1drv.com/y4m...&cropmode=none
https://zynpaq.dm.files.1drv.com/y4m...&cropmode=none
https://ziniaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinhaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinjaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinmaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinlaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinoaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinnaq.dm.files.1drv.com/y4m...&cropmode=none
https://zinqaq.dm.files.1drv.com/y4m...&cropmode=none

Tooling coat thermal heat:
https://asniaq.dm.files.1drv.com/y4m...&cropmode=none
http://www.youtube.com/watch?v=EKjQyB11Cns

First skim coat of tooling gel:
https://asnhaq.dm.files.1drv.com/y4m...&cropmode=none
https://asnkaq.dm.files.1drv.com/y4m...&cropmode=none
https://asnmaq.dm.files.1drv.com/y4m...&cropmode=none

Knocked out a few high areas
https://asnlaq.dm.files.1drv.com/y4m...&cropmode=none
https://asnoaq.dm.files.1drv.com/y4m...&cropmode=none
https://asnnaq.dm.files.1drv.com/y4m...&cropmode=none
https://asnqaq.dm.files.1drv.com/y4m...&cropmode=none

Gelcoat applied again to fill in low spots (will need additional coats)
http://www.youtube.com/watch?v=fcJmvPfokBU

gbrettin 04-22-2020 09:37 AM

IG@gbrettin:
Most all area are coming out great. Only a few touch up areas are needed. Tooling gel is incredibly hard. I've been at this with 60grit and changing the sanding pad many times. Moral of the story? Do your mould correct the first time. If you can't... Then you can repair with many hours of sanding. Many hours.. many many...

---------------

All this time sanding gives me time to reflect how I would do the moulding process. Doing it again, I would start it off like this:

These steps were fine: flange construction, clay, Partel Wax and PVA.

Corrective steps:
Tooling gel coats (Weekend process):
1. In the AM. Apply 1 coat of tooling gel. (Orange or Red)
2. In the Evening. Apply 1 coat of tooling gel. (Orange or Red)
3. Next day. In the AM apply 1 coat of tooling gel. (black)
4. Afternoon - 2 layers of fiberglass (lighter fiberglass) using tooling polyester resin (2gal)

Next Weekend
5. 4 layers of heavy fiberglass. using tooling polyester resin (4gal)
6. Next day same as step 5.

Couple days later
7. evaluate for additional layers or pop mould.

I think that would yield the perfect mould or atleast have minimal repair.

This pictures below are about 6 hours of sanding. You may have asked yourself why I didn't start over? I have hundreds of dollars into the mould materials. Each tooling polyester gallon is about 40 dollars. I have about 7 gallons on my hood mould. Tooling gel costs about the same. Good fiberglass is about 4 dollars a yard. I used about 15yds (guessing). And so on. SO there is the cost but also the time of setup. Most importantly, I think it's worthwhile to fix the mould and show everyone the long road if you're new at something.

Thanks for watching my crazy build process so far.

https://zsnqaq.dm.files.1drv.com/y4m...&cropmode=none
https://zsnpaq.dm.files.1drv.com/y4m...&cropmode=none
https://zcniaq.dm.files.1drv.com/y4m...&cropmode=none
https://zcnhaq.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 04-22-2020 09:39 AM

Important note!

I'm waiting on parts for my hot and coldside. Not a lot happening with the engine side of things, so I'm happy I have this side project.

Hotrodz 04-22-2020 04:55 PM

You are killen it my friend. Can't wait to see that beast at ZDAYZ!

Sent from my SM-G965U using Tapatalk

Rusty 04-22-2020 10:09 PM

Hook up a shop vac to that sander. Use a flexible hose long enough to let you move around the hood. You'll thank me later. :tiphat:

gbrettin 04-23-2020 08:58 AM

IG @gbrettin:
Knockdown, test fit and fill... Yup. Again. All the problem areas have subsided. Last time going through the rough grit on this. I can start working on wet sanding next.

-----------------------------

I know these posts are a bit repetitive; but, it'd rather show what actually goes into the actual mould making process.

Hotrods - The Dewalt has a little bag that has been catching 85% of the dust (which has been amazing). I just so happen to have a small shop vac at the shop. I'll hook that up!

Something to be said about the edges on the mould... I have the edges roughed out and will need to dedicate a ton of hours getting them perfect. I have been slowly building the edges up, specifically with tooling gel since it's hard AF.

It's getting there.

More sanding supplies
https://aimgxw.dm.files.1drv.com/y4m...&cropmode=none

Test fit. Edgest will be built up.
https://bsmzxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmgxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmyxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmbxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmdxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmcxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmexw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmhxw.dm.files.1drv.com/y4m...&cropmode=none
https://bsmgxw.dm.files.1drv.com/y4m...&cropmode=none
https://bcmzxw.dm.files.1drv.com/y4m...&cropmode=none

More Sanding
https://bcmexw.dm.files.1drv.com/y4m...&cropmode=none
https://bcmhxw.dm.files.1drv.com/y4m...&cropmode=none
https://bcmgxw.dm.files.1drv.com/y4m...&cropmode=none

Skim Coat
https://zsniaq.dm.files.1drv.com/y4m...&cropmode=none

Rusty 04-23-2020 01:51 PM

I have the same DO sander. That bag doesn't catch chit. When I'm using mine. I duct tape my shop vac to it. It will also make your disks last longer too.

gbrettin 04-24-2020 07:01 AM

IG @gbrettin:
Needs 1 more day of cure because it's still cold here. The lines look great, no more pin holes and no more fiberglass patterns showing in the tooling gel. The perimeter needs to be cleaned up. No worries, I have a plan!---- *Runs off and makes plan*

Starting the Sunoco cowl 370z plug. Part B of my mould. Whipples and high rams rejoice!

-----------------------------------------------------------------

The mould looks to be coming to a close pretty soon so I'm ramping up on making a plug for the cowl. All the lessons I learned from the hood will be dumped into making the sunoco style cowl. The pictures below is me just roughing a mental idea out. I could draw it on paper with proper dimensions but I don't see the point. I need to visually feel out the lines to see how they make me feel.

I'm also going to make two rough plugs. The first one will be constructed from the items you see below. The second plug will be from my buddy's Mustang cowl. In all honesty, I really like the shape of the Mustang cowl so I want to give that a test first. I purchased expanding foam from Composite Envisions. The foam can be poured into the cowl portion of the hood and then I can cut/sand the foam down. Perhaps I can get out to the shop tonight and make that foam plug.

I'm in the design phase so any and all thoughts are welcome.

Dried(ing) tooling gel
https://aymexw.dm.files.1drv.com/y4m...&cropmode=none
https://aymhxw.dm.files.1drv.com/y4m...&cropmode=none
https://aymgxw.dm.files.1drv.com/y4m...&cropmode=none

Cowl construction
https://aimzxw.dm.files.1drv.com/y4m...&cropmode=none
https://aimyxw.dm.files.1drv.com/y4m...&cropmode=none
https://aimaxw.dm.files.1drv.com/y4m...&cropmode=none
https://aimdxw.dm.files.1drv.com/y4m...&cropmode=none
https://aimcxw.dm.files.1drv.com/y4m...&cropmode=none
https://aimfxw.dm.files.1drv.com/y4m...&cropmode=none
https://aimexw.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 04-25-2020 07:56 AM

IG @gbrettin:

I plan on making two plugs. First one will be hand made and the second is a direct plug off a different hood. I'll see what works better soon. And guess what! Another coat (say it like DJ Khalid).

---------------

Nothing new that you guys don't already know (from my IG statement). I will say this though... I ALMOST thought about dumping my foaming compound directly into the carbon fiber cowl you see below. The foam has some of the same chemicals used to lay up carbon fiber. It would have etched into the cowl ruining his hood if I didn't pull ripcord.

I'll put some plastic down and then make a plug today.

https://aymaxw.dm.files.1drv.com/y4m...&cropmode=none
https://aymdxw.dm.files.1drv.com/y4m...&cropmode=none
https://aymcxw.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 04-26-2020 07:43 AM

IG @ gbrettin:
Made me a big ol' hot pocket. �� Hot pocket ��

I needed a less dense A B foam mix and more of it. Great Stuff to the rescue. .... A few cans later... This hot pocket has been filled. ��

https://acmzxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmyxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmbxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmaxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmdxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmcxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmfxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmexw.dm.files.1drv.com/y4m...&cropmode=none
https://acmhxw.dm.files.1drv.com/y4m...&cropmode=none
https://acmgxw.dm.files.1drv.com/y4m...&cropmode=none
https://aymzxw.dm.files.1drv.com/y4m...&cropmode=none

Rusty 04-26-2020 01:01 PM

Which Great Stuff did you use? The triple expanding stuff. You have to be careful of. It WILL push things apart. Don't ask me on how I know. :facepalm:

gbrettin 04-27-2020 09:23 AM

:tup:
Quote:

Originally Posted by Rusty (Post 3929230)
Which Great Stuff did you use? The triple expanding stuff. You have to be careful of. It WILL push things apart. Don't ask me on how I know. :facepalm:

Oh yeah, she was ready to burst at the seams. lol

I filled in some pockets with MORE great stuff.
http://www.youtube.com/watch?v=yezXMiCPn0o

https://asmbxw.dm.files.1drv.com/y4m...&cropmode=none
https://asmaxw.dm.files.1drv.com/y4m...&cropmode=none
https://asmdxw.dm.files.1drv.com/y4m...&cropmode=none
https://asmcxw.dm.files.1drv.com/y4m...&cropmode=none

BettyZ 04-27-2020 02:00 PM

Needs more duct tape.

Sent from my SM-G955U using Tapatalk

gbrettin 04-28-2020 01:34 PM

IG:@gbrettin
Well that was a pretty significant fail... 😂

Plug v1 found its forever home.

Starting sand out properly.

-----------------------------------------------------

Ordered a few more parts from Motion Raceworks. I think I'm down to a ordering a driveshaft now, last major purchase I know of. Outside of that.... I think I have everything needed to make it run. If not, the parts store has the rest.

https://zymgxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimzxw.dm.files.1drv.com/y4m...&cropmode=none
https://zymhxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimyxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimbxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimaxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimdxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimcxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimexw.dm.files.1drv.com/y4m...&cropmode=none
https://zimhxw.dm.files.1drv.com/y4m...&cropmode=none
https://zimgxw.dm.files.1drv.com/y4m...&cropmode=none
https://zymexw.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 04-30-2020 09:58 AM

IG@gbrettin:
Motion Raceworks coming through with quick shipping and notifications to my cell. FedEx guy is super excited about my build after frequently making stops to my house too. ��

Perfect fit with OE exhaust manifold, Firecore plugs, Motion Raceworks coil mounts, MS3 IGN-1A coil packs. I must say, the Motion Raceworks billet valve breathers are damn nice too

These Black Sheep Industries cold side clamps look like the business. Can't wait to get them welded up.

Guide coat, aka white spray paint, is showing me high/low spots. Only have a few problem areas left near the front. Don't mind the white strips near the center. I need to do those sections by hand.

--------------------------------------

For some reason I didn't get pictures of all the stainless steel, BOV, Wastegates and boots. All my boost components are in. My buddies, Dave and Nick, are getting a few major projects out the door. I suspect we will start welding a few things up in short order. Heck.. I might just start tacking some piping together. Hmmmm. Yeah I'll do that.

I was going to use a coupler boot, 4in to 3in, but have decided to go with a coldside clamp off the throttle bodies. Honestly, I don't like the look of rubber couplers. I'll need to find an aluminum reducer from 4 to 3 and order two more vbands (same Black Sheep Industries).

I have most all of the fuel components and AN cooling lines... so I will be getting that figured out as well (parts trickling in for those items make me feel not as bad about spending 20 bucks on a single fitting).

https://zcmexw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmzxw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmyxw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmbxw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmcxw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmaxw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmfxw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmexw.dm.files.1drv.com/y4m...&cropmode=none
https://zsmgxw.dm.files.1drv.com/y4m...&cropmode=none
https://zcmzxw.dm.files.1drv.com/y4m...&cropmode=none
https://zcmyxw.dm.files.1drv.com/y4m...&cropmode=none
https://zcmbxw.dm.files.1drv.com/y4m...&cropmode=none
https://zcmaxw.dm.files.1drv.com/y4m...&cropmode=none
https://zcmdxw.dm.files.1drv.com/y4m...&cropmode=none
https://zcmcxw.dm.files.1drv.com/y4m...&cropmode=none

madwi 04-30-2020 10:10 AM

What a good looking build. Cant wait to see and hear this thing.

gbrettin 05-01-2020 07:58 AM

IG:@gbrettin

Needed a quick and easy win. Had these laying around for.... Three years. Old covers were a bit fatigued and I broke them .... Or at least that's the story I'm going with.

-----------------------------------------------

I did some work on my hood mould last night but didn't post it to IG... heh. I'll post the pictures here because I feel like torturing your eyeballs. I worked the corners of the mould and see that I can get the mould very close to OE; however, my buddy Nick and I came up with the idea to remould the corners back in. This will allow me to build up a defined lip on the mould and build up a nice transition to the flange. To implement that I will need to sand down the edges close, which that's what I am doing now anyhow. I'll prep the hood with release agent and PVA on the corners. Then I will build up around the edges with tooling gel a few times. You've seen how hard that stuff gets.

Update on the cowl plug. I'm pretty dead set on using Dave's Mustang cowl and modifying that. I ordered a few cans of 4lb density foam filler for the Sunoco cowl. What I am going to do different this time is build up a nice cardboard backer again and strap it on similar to what I did last time. What is going to be different is that I will lay the hood flat and pour smaller amounts of the 4lb density foam in. The cardboard backing will have a few relief holes. That will allow the foam to breath a bit and flow out as needed. Less tape will be abused on this cardboard backer.

Pulling the outer pillar cover was slightly disappointing. I wanted to keep the OE covers around. I was going to get a panel pulling tool... NAH, I went beast mode and pulled it straight back like an ape. I guess I'm not that disappointed. lol

Lastly, I ordered two more 4in vbands, 4 to 3in reducer and a few fragola fittings. Now if you have never ordered AN style fitting... let me be the first to tell you.... those little MF'ers can cost as much as a major component on a build when you tally up all of them. Brother vband must be related to the AN's because that is just about the same type of d1ck kick.

-- EDIT

The window stickers "the370z.com" is coming down in favor of my car sponsor "MS3Pro". Sorry the370z.com, you been good.... but I like discounted parts better.

https://bskd6w.dm.files.1drv.com/y4m...&cropmode=none
https://bskg6w.dm.files.1drv.com/y4m...&cropmode=none
https://bskf6w.dm.files.1drv.com/y4m...&cropmode=none
https://bcnp6g.dm.files.1drv.com/y4m...&cropmode=none
https://bcn96g.dm.files.1drv.com/y4m...&cropmode=none
https://bcnq6g.dm.files.1drv.com/y4m...&cropmode=none
https://bckb6w.dm.files.1drv.com/y4m...&cropmode=none
https://bcke6w.dm.files.1drv.com/y4m...&cropmode=none
https://bckg6w.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 05-01-2020 08:08 AM

:roflpuke2: FYI, I just saw that I needed to pop the top of the pillar cover and then slide up...:roflpuke2:

:icon14:

gbrettin 05-04-2020 01:03 PM

IG @ gbrettin:
With the powers combined. *Transformer noises* meet plug v2.

Still expanding but looks like I fell a tad short again. No worries. I'll get more of the foam... Proper expanding foam, like what's in there.

----------------------------------

I took an inventory shot to see how much needs to be done. It looks like a lot, but I really don't think it's that bad.

I sent in another order for foam. I said screw it, and ordered two gallons. I'd prefer not to run out again.

Using the hood for the backer is working out awesome.

I was planning on getting to the shop this weekend... but my wife presented me with a list of things to get done around the house. There's no way of getting out of that... I mean, she's been REALLY cool about me staying late at the shop.

https://aikc6w.dm.files.1drv.com/y4m...&cropmode=none
https://aike6w.dm.files.1drv.com/y4m...&cropmode=none
https://aikd6w.dm.files.1drv.com/y4m...&cropmode=none
https://bsnp6g.dm.files.1drv.com/y4m...&cropmode=none
https://bska6w.dm.files.1drv.com/y4m...&cropmode=none
https://bskc6w.dm.files.1drv.com/y4m...&cropmode=none
https://aikf6w.dm.files.1drv.com/y4m...&cropmode=none

madwi 05-04-2020 04:21 PM

Coming along great, man. :tup:

gbrettin 05-07-2020 11:19 AM

IG@gbrettin
Chop chop. Cut the Holley crossover line that came with the twin plenum and put some ends on it. Then connected them into the fuel pressure regulator. Return line will shoot directly back over the valley pan.

Pin on hood testing my patience tonight. Throwing in the dusty towel.

------------------------------------

Block sanding the mould last night burned me out. Someone messaged me and asked me if I was giving up on it. Absolutely not. It's normal to fee frustrated in a project. I just stopped for the night and will hit it again tonight, tomorrow and the day after. What ever needs to be done to complete it. Frustration comes from my own level of expectations, it needs to be the absolute best work I can do. I'll know when it's there.

My order for 2 gallons of expanding foam should be here today. I should be able to have the rough plug done tonight. That's exciting stuff!

Yesterday I was looking at the cooling system lines and found something where I can use my OE radiator and adapt to -16 AN. Auto Plumb has a cool adapter. I'll use that until I change out my radiator down the road. Who knows, maybe I can keep the OE radiator (wishful thinking).

-- EDIT
I tried getting my finger bleeding in the picture for you guys. lol. The metal stabbed the **** out of my finger.

-- EDIT EDIT
The fuel line was sprayed out with brake cleaner and then air. That's an FYI for anyone wanting to do their own AN lines.

https://zinq6g.dm.files.1drv.com/y4m...&cropmode=none
https://zikc6w.dm.files.1drv.com/y4m...&cropmode=none
https://zin96g.dm.files.1drv.com/y4m...&cropmode=none
https://zika6w.dm.files.1drv.com/y4m...&cropmode=none
https://zikb6w.dm.files.1drv.com/y4m...&cropmode=none
https://zike6w.dm.files.1drv.com/y4m...&cropmode=none
https://asn96g.dm.files.1drv.com/y4m...&cropmode=none
https://zikd6w.dm.files.1drv.com/y4m...&cropmode=none
https://zikg6w.dm.files.1drv.com/y4m...&cropmode=none
https://zikf6w.dm.files.1drv.com/y4m...&cropmode=none

Ghostvette 05-07-2020 11:51 AM

:tup:

The attention to detail on this build is awesome. I can't wait to see it done. Hopefully, I can see it run.:excited:

gbrettin 05-08-2020 01:56 PM

Plug v2 is growing! Reminds me of expandable toys as a kid during bath time mixed with rice crispy treats.

I know it doesn't look like much, but this will work! Most all the shape is there in the right areas. Marglass and fiberglass sheets will get it there. 😁

----------------------------

I decided to stop posting pictures of progrogression sanding on my IG. I'll post the pictures here though. It might not be exciting but at least you can follow the level of involvement needed

The plug v2 could have been better with a lot of foam mix to start with but I have what I have. I have enough surface area from the cowl to form a cowl from fiberglass. It's a little extra work but what ever.

I'm thinking I can get the cooling system routed all by this weekend. The fuel system can also be started. The gas tank of my car is completely full of fuel that's two years old. I'd imagine it would be good for a lawn mower at this point. That's going to suck draining.

http://www.youtube.com/watch?v=P1ekm_5g2eY
http://www.youtube.com/watch?v=y5ygIYdhdl4
https://zcka6w.dm.files.1drv.com/y4m...&cropmode=none
https://zcnq6g.dm.files.1drv.com/y4m...&cropmode=none
https://zckc6w.dm.files.1drv.com/y4m...&cropmode=none
https://zckb6w.dm.files.1drv.com/y4m...&cropmode=none
https://zcke6w.dm.files.1drv.com/y4m...&cropmode=none
https://zckd6w.dm.files.1drv.com/y4m...&cropmode=none
https://zckg6w.dm.files.1drv.com/y4m...&cropmode=none
https://zckf6w.dm.files.1drv.com/y4m...&cropmode=none
https://zynp6g.dm.files.1drv.com/y4m...&cropmode=none
https://zyn96g.dm.files.1drv.com/y4m...&cropmode=none
https://zyka6w.dm.files.1drv.com/y4m...&cropmode=none
https://zyke6w.dm.files.1drv.com/y4m...&cropmode=none

gbrettin 05-10-2020 11:07 AM

I lead off my removing my passenger seat. That's highly recommended if anyone is going to change out their pump. it made life easy, besides; it's only four bolts to get it out.

In true form, I jumped into the fuel pump swap with out reading the directions. None were included with the pump bracket but it was straight forward. I sent Charles a few questions but ended up answering my on question prior to him getting back to me (he's always good at getting back to me btw).

The CJM bracket is machined awesome. I was able to look at my old pump housing and move over the sensor after staring at it like a dumb monkey for a few. One thing that threw me off was the fuel temp sensor, I didn't even know that OE had that. The sensor was removed because it's not needed. On the fuel pressure regulator I installed a RIFE which does pressure and temp.

Last pictures show the Autoplumb AN lines for the radiator. I put it on then took it back off. There's an online video w/ directions that I need to go through.

https://zske6w.dm.files.1drv.com/y4m...&cropmode=none
https://bcnwsa.dm.files.1drv.com/y4m...&cropmode=none
https://zsnp6g.dm.files.1drv.com/y4m...&cropmode=none
https://zsn96g.dm.files.1drv.com/y4m...&cropmode=none
https://zska6w.dm.files.1drv.com/y4m...&cropmode=none
https://zsnq6g.dm.files.1drv.com/y4m...&cropmode=none
https://bsnssa.dm.files.1drv.com/y4m...&cropmode=none
https://bsntsa.dm.files.1drv.com/y4m...&cropmode=none
https://bcnosa.dm.files.1drv.com/y4m...&cropmode=none
https://bcnrsa.dm.files.1drv.com/y4m...&cropmode=none
https://bcnqsa.dm.files.1drv.com/y4m...&cropmode=none
https://bcntsa.dm.files.1drv.com/y4m...&cropmode=none
https://bcnssa.dm.files.1drv.com/y4m...&cropmode=none
https://bsnqsa.dm.files.1drv.com/y4m...&cropmode=none
https://bsnvsa.dm.files.1drv.com/y4m...&cropmode=none

Auto plumb
https://bsnwsa.dm.files.1drv.com/y4m...&cropmode=none
https://bsnxsa.dm.files.1drv.com/y4m...&cropmode=none

Rusty 05-10-2020 12:13 PM

When I did phunk's RRP kit. I took both seats out plus the rear plastic panels to make my life better.

gbrettin 05-10-2020 08:30 PM

Yeah, I have a feeling the carpet will be coming up because wiring will need to go in soon.

Sent from my SM-G975U using Tapatalk

jchammond 05-10-2020 09:09 PM

Looking Good; trying to wind up my garage & then knock out a few things before starting on the Z...lately has been like :wtf2:


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