Just a quick note: I apologize for any redundancy regarding the pics that may occur...I just want to make sure I cover everything, because there is a large gap in the blog.
I'll start with the intake:
This past year, we had a lot of trouble with the intake system. For some reason, the epoxy we were using would sometimes cause small imperfections, and then when we placed the entire intake under vacuum, those weak spots would cave in and case us to remake the intake (about 4 times total).
For the runners themselves, we stuck with carbon fiber because of the large radius of curvature and focus on lightweight design. In order to successfully do this, we had to use wax molds that we wrapped in carbon fiber, and then melted the wax out (we're looking to refine this process for next year).
|The molds full of wax|
|Runners: Good! Plenum: Not so good...|
|New plenum support substructure|
Once we had the intake, we then needed to machine fuel injector bungs and place them properly on the runners. Our design thought was to mount the injectors close to the intake ports so that the fuel would not compromise the structural integrity of the runners (we noticed that it weakened the runners over time due to large amount of exposure to the race fuel).
|Aligning the injector bungs and the mounting structure|
Once we got everything secured and sealed, the final product was ready to mount on the car!
|Finished intake assembly|
Stay tuned for more updates...didn't want to put too many things on one blog post!