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My wing fabrication, the progression


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getting ready to fab the endcaps

http://www.fileden.com/files/2007/2/3/727626/IMG01032.jpg

http://www.fileden.com/files/2007/2/3/727626/IMG01033.jpg

http://www.fileden.com/files/2007/2/3/727626/IMG01034.jpg

http://www.fileden.com/files/2007/2/3/727626/IMG01036.jpg

http://www.fileden.com/files/2007/2/3/727626/IMG01037.jpg

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  • 3 weeks later...

Nice work, I've never used Great Stuff for fiber-glassing but it's a good idea - I've used balsa wood and styrofoam as a base. I have to say I love the exhaust. Did you have to cut the pan slightly to get it it to work?

 

Edit: I found your build thread. Looks good.

Edited by modifyd
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Great stuff is ok to work with in small areas, I prefer styrofoam but in this case it was easier this way. Great Stuff needs a lot of room to expand or it will have big air bubbles that will be wet on the inside, PITA, but it works...I just have to fit my third brake light and I'm done.
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Did you finish the exhaust work up? In your build thread, i just saw that you had begun making covers for it. I was thinking you could just make that part of the piping integral with the car (i.e. weld it solid to the chassis) and have it connect to a flex connection under the car - this will help with your sealing issues as well. The reason I say that is I plan on running my dump tube out of the fender and thats how it will be done.

 

Yeah, I've used Great Stuff in other things before and it's fairly easy to work with once dried - you just have to make sure it has plenty of room and the surrounding materials are stiff or else it will push them out. You can actually carve it with an electric carving knife.

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Did you finish the exhaust work up? In your build thread, i just saw that you had begun making covers for it. I was thinking you could just make that part of the piping integral with the car (i.e. weld it solid to the chassis) and have it connect to a flex connection under the car - this will help with your sealing issues as well. The reason I say that is I plan on running my dump tube out of the fender and thats how it will be done.

 

Yeah, I've used Great Stuff in other things before and it's fairly easy to work with once dried - you just have to make sure it has plenty of room and the surrounding materials are stiff or else it will push them out. You can actually carve it with an electric carving knife.

Unfortunately, you can't make any part of your exhaust solid with the car. The combination of heat and vibration make for a 100% chance that something is going to crack, even with the flex connector. I have the part that goes through my cabin floating on urethane bushings.

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I think it should be OK rigid that far back, i don't think the thermal expansion would be that great and a good flex coupling should keep the movement due to the engine in check. I remember Billy Lane made an exhaust as part of one of his bike's frame. Anyway, it looks good, I'm ready to see your car look like your signature.
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I think it should be OK rigid that far back, i don't think the thermal expansion would be that great and a good flex coupling should keep the movement due to the engine in check. I remember Billy Lane made an exhaust as part of one of his bike's frame. Anyway, it looks good, I'm ready to see your car look like your signature.

 

the only problem, a motorcycle's engine doesn't move in the frame, they're hard mounted. So there's no flexing in that setup.

 

if you hard mounted your exhaust, you'd want multiple flex sections, one for fore-aft movement in the downpipe, and another one or two under the car for side-to-side and up-down movements. Remember, flex sections are there to move side to side, not to compress (was proven they fail when under compression forces, from being mounted on the downpipe only)

 

ALSO, remember on that bike, he had heat issues on the ride. although your butt won't be sitting an inch off the exhaust, it's not gonna be good for the metal of the unibody, as stated above, your gonna run the possibilities of cracking and prematurely fatiguing the metal from the heat, so in the event of an accident, it's gonna be weaker than before.

Edited by D_Venable
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For tension/compression use a bellows-type flex connection:

 

http://img109.imageshack.us/img109/3503/oemuppipe1a.jpg

 

You're thinking of the braided ones which are good for lateral motion. I'll agree with you on heating the surrounding metal and it may eventually (long time) make it more brittle, but I don't think it would be significant - especially since its basically free flowing past the resonator or muffler (save for the K-loss in the bends). And yeah I forgot about the bike's engine being rigid, but thermal factors still weigh in on that aspect.

 

 

 

mistapickles,

I can't tell from your signature picture, but do you have any plans for the rear bumper or are you going to leave it as is?

Edited by modifyd
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For tension/compression use a bellows-type flex connection:

You're thinking of the braided ones which are good for lateral motion. I'll agree with you on heating the surrounding metal and it may eventually (long time) make it more brittle, but I don't think it would be significant - especially since its basically free flowing past the resonator or muffler (save for the K-loss in the bends). And yeah I forgot about the bike's engine being rigid, but thermal factors still weigh in on that aspect.

 

 

 

mistapickles,

I can't tell from your signature picture, but do you have any plans for the rear bumper or are you going to leave it as is?

Heating of the surrounding metal can be averted with a simple heat shield. I laser temped the exhaust at just idle and it got to 315f, so under load I'm sure it got hotter than that. 14-12 gauge pipe, at 315+ degree temperature just idling is going to crack that piping wherever it is connected to something not buffered. Throw in the fact that your car is going to hit 5000 more rpms under load and its happening sooner not later. Trust me, I wanted the part in the car to be solid, but every custom exhaust guy I talked to said it wouldn't work out, you don't want a cracked exhaust pipe on the inside of your car.

 

The rear bumper is staying stock, although I am cutting out my spare tire area in the floor and fitting a custom gas tank that'll allow me to make a diffuser fit under my car.

Edited by mistapickles
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  • 2 weeks later...

Now that it's not 14 different shades of primer and filler it's easier to see and I think I like it much much better...I even had a couple hot girls check me out in it...apperently women didn't like the urban primer camo look I had before.

 

http://www.fileden.com/files/2007/2/3/727626/IMG01063.jpg

http://www.fileden.com/files/2007/2/3/727626/IMG01061.jpg

http://www.fileden.com/files/2007/2/3/727626/IMG01062.jpg

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I need those back lights

 

My starting point. The window edge is shaped wrong, the wing is too narrow and it's got a bow in it towards the window, doesn't lie flat against the hatch.

http://www.fileden.com/files/2007/2/3/727626/P1140064.JPG

http://www.fileden.com/files/2007/2/3/727626/P1140066.JPG

http://www.fileden.com/files/2007/2/3/727626/P1140067.JPG

http://www.fileden.com/files/2007/2/3/727626/P1140070.JPG

 

cut the under side out and shaped the front edge to match the window line.

http://www.fileden.com/files/2007/2/3/727626/P1140072.JPG

 

after cutting and fitting for an hour and reshaping the side wings...

http://www.fileden.com/files/2007/2/3/727626/P1140076.JPG

http://www.fileden.com/files/2007/2/3/727626/P1140077.JPG

http://www.fileden.com/files/2007/2/3/727626/P1140078.JPG

 

Tomorrow I get to do the side with the antenna on it...yeah and make a spot for the third brake light....

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i think he wants starion tails=P lol I like my Quest tails, and i had a set of Starion tails but they came badly cracked (was told they were fixable...way to many inside lens cracks) But my Quest tails look amaqzing=D only other tails i'd do are they trendy, yet amazing 83 tails=) You getting a new drivers side tail? looks like you had a nice fandango there to bust it...=O
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I have the tail light sitting on a shelf in the garage...when I put the engine in I'll put it on...I'm thinking of having a car build bbq, where I invite all my mechanic friends over and we put my engine in, fix my trans leak and finish my 3" conversion on my side exhaust and I buy the beer and food.

http://www.fileden.com/files/2007/2/3/727626/P5300088.JPG

http://www.fileden.com/files/2007/2/3/727626/P5300089.JPG

Edited by mistapickles
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  • 2 weeks later...

did you alreaqdy hit the curb with the passenger side of your airdam? lol looks like it's mossing paint. looks good though

I actually haven't done anything with the air dam at all, it's cracked way worse on the other side. I haven't decided what I'm going to do to customize it.

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