How To Make Composite Intake Tubing (easy)
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- เผยแพร่เมื่อ 7 ก.ย. 2024
- A cheap and easy way to make your own composite intake tubing. Welcome to The Fab Forums, and part of the Fabrication Nation. In this video I go over an easy way to make your own composite intake tubing.
Get casting tape here: amzn.to/1MsGPa1
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I watched your videos, I’m using this method now with a 3D printed pipe as a mold... I got black casting tape. One thing... 100% wear gloves... my hands are now dyed black, brake clean won’t take it off LOL. Awesome videos and advice! Keep it up
I'm a little to the party. but the cast wrap is total genius. keep up the good work. your video on shark hide was a life saver. ive got a 70 challenger that ive built aluminum tin panels for the entire engine bay like 7 years ago and it been a constant battle to keep them looking nice.
thanks, glide I was able to help
I dig it, I'm going to use your technique and some foam pipe insulation or pvc (as a mold) to produce my own intake as a project. Thank you
+chaley thom no problem....tag me on photos of your finished product
Just so you know, this is how some multi million dollar teams in F1 manufacture their intake systems. They didn't start doing this until 2015, so I'm just going to assume they got the idea from here.
The only difference is they have better materials for forming the intake.
From there they coat the inside with a little extra epoxy and then port the inside to a smooth finish.
If you have ever seen an F1 intake made from carbon fiber, its very rough and textured on the outside even though its carbon fiber, while being very smooth on the inside.
Just goes to show you can get great ideas from anywhere!
Thats awesome !
"so I'm just going to assume they got the idea from here"
Please tell me you're kidding.
@@subasurf you never know
Thats insane!
If you made the pieces out of styrofoam and layup the carbon fiber or fiberglass on it after it cures the styrofoam can be removed with acetone. Then you can avoid cutting it apart after. Just an idea.
I DIY'd a true CAI for my 2006 Pontiac GTO. Removing & relocating the overflow tank with a DIY'd aluminum bottle in the engine bay gave me enough room behind the left fog light inside the bumper to holesaw a 4.5 inch hole and route 4inch PVC tube with a small Spectre pancake filter. Not liking the PVC "Ghetto" look taking away from the absolutely fabulous LS3, I searched for another DIY method. Came across this video last week, ordered the 3M black casting tape X's 2 and I'm about to get down making the mold as soon as I send this & get my a$$ off the toilet. Thanks for the excellent idea & video!!!!
I watched your pressure testing video with the carbon fiber wrapped casting. You had to drill into it and install bolts that eventually blew out. I had an idea that might solve that without bolts. When you wrapped the cast with carbon fiber, place on each end a metal pipe as far back as the rubber connectors go onto the pipe, along with a slight flange similar to how radiator ends are to help reduce the possibility of the hose from slipping off. Not only would the metal pipe help with the connector to not fall off but it could also allow you to tighten the clamps a bit more without risking the intake pipe from cracking. Awesome videos and great ideas man!👍
justin mesa Thanks...I thought about doing the same. In this video I was trying to come up with a good way to hold the coupling after I had already made the tubing. I didn't know I would be pressure testing this tube when I made it.
How do they stand up to engine heat? Any risk of it breaking down and being sucked in through your engine? I really like the idea of being able to mold my own intake pipe!
When you wrap don't overlap each turn around the mold you can cover the seams by offsetting the 2nd wrap. Try running the fiberglass lengthwise and don't overlap. This should give you a smoother surface inside and out. This may be hard to do on sharp turns.
This is super cool, my only concern is its made of fiberglass, obviously im sure your filter wouldnt let any in the engine but do you think its a concern?
This is still relevant after 8 years; wow! I'm trying to figure a way to make a MAF sensor mount/bung from a material that is both good with under hood heat and that can be worked in between wrap (or mat) layers. What can be drilled for a round MAF sensor and then be thick enough to hold in the sensor screws and not crack (that's not metal)? Maybe a salvaged piece of engine bay plastic from a junkyard car. Or a MAF sensor mount from the same make junk vehicle!
there are two methods for making tubing and stuff like that . one is using a female mold (on the outside of the part) , and laying the carbon on the inside before mating the halves of the mold, and using baloons (with the appropriate shape) , you blow them up inside the mold and they press the carbon on the inside of the mold. this has more pressure than vacuum bagging, and results in a pristine surface. its the method that lamborghini uses to make braces on top of the engine for the spider models. the other method is using a water soluble concrete-like stuff, which you fill the mold up with, and then bake to get rid of all moisture. this results in a male mold, which dissolves with water when you re done. you use vacuum bagging on this method. ideally, for piping, you dont use a bag, but a pipe that heat shrinks. if you want i can give you links for these products but they are from a german company.
lol...why my method is easier than both of those
your method results in a poor finish and the other methods result in stronger composites (because vacuum bagging has a max. pressure of 1 bar (because it relies on atmospheric pressure) and balloons and shrink tapes or tubes have 7-20 times the pressure of that. if you lol all the time, you won't learn anything new.
This is pretty cool. You should probably sand off a couple of mm before gluing back together though, otherwise your new pipe has a wider diameter. Do you know if this stuff holds up to oil? (I got an Audi 2.0tfsi, not uncommon to find some in the intercooler piping if the pcv valve fails).
Have to go and watch you doing the carbon fibre now.
Thanks
Thanks for the second video on the tubes! Would be great to figure out a way to connect hose sleeves, so they dont blow off. If adding a rolled end works or what
Cam Shaft Thanks...I will working that to see what I can come up with
TheFabForums.com hey just roll a bead into your mold pipe and wrap it with the cast
Yea that would probably work but I think I need to come up with something that will reinforce the ends some.
Never understand the thumbs down in any of your videos. I'd like to do a carbon fibre wrap on the hood and tailgate of the '80 Powerwagon. It would leave a lot of people thinking what the fawk. Would like to see you do a build on an early Dodge 4x4. Mine's available for practice LOL
some people are so un happy with themselves they cant find good in anything else
shit what a great bloody idea! I love DIY stuff like this, pure brilliance.
my only concern would be its porosity BUT you could easily brush resin over it once removed from the plug and the casting resin has hardened totally. so cool!
+flyingbrick88 thanks...I have actually coated and sanded for finished look
+The Fab Forums yeah I see that now in your other video. love your work!
Hey, just came across your videos. You're half way there, but there is an easier way! Firstly, if you want to capture more detail from the original part, use plaster of paris to take the mold instead of fiberwrap. Second, you're fine to cut the mold line, like you did and then staple/re-wrap over it to get it back together nice and strong.
Here is where easy comes in:
- Wrap one end closed so its shut. Let cure.
- Spray water/dish soap solution into your mold (not too much, enough to wet all the inner walls)
- Place part into sand/stand/whatever to keep it upright with the OPEN end on top.
- Mix and fill with plaster. Allow to cure.
- Cut and remove cast to reveal the mold.
- If needed, wet the new cast and you will be able to mix more plaster and correct any imperfections or make modifications to the mold.
Now you have the perfect mold to wrap with carbon/fiberglass. You can buy carbon weave tubing (sleeve), pull over part, saturate, put into vacuum.
lol....sounds way more complicated
Man, you are a genius! Thank you!
Thanks
The Fab Forums , so if you are trying to sport up or improve a stock intercooler system for a vehicle, you could just use the existing piping as the mold for the project correct?
Absoluetly awesome, mate; you are the man!
Great video, nice idea.
Those 3M wraps cost ten times the price you pay, here in Germany...
Not cheap for me. :-(
Haha ging mir gerade genauso ...schau mal nach 3M Scotchcast stützverband (Ebay nummer 151081831742)
oder frag beim Hausarzt nach ob er dir zu besseren preisen weiterhelfen kann
Hey man thanks there’s my solution for my compound turbo set up
hey, i have watched a bunch of your vids with this composit/ carbon wrapping. Your main point lighter with resistance to heat as opposed to aluminum. do you have any vids supporting? maybe with a few temp sensors and heating the cast. aluminum, then composite cast, then composite cast with carbon? maybe even aluminum with composite wrap? please if you can, that would be a great video to know temperature integrity. thank you
I dont have any, but it doesnt really take any sensors. You can tell a huge difference just by touch. The aluminum will heat soak and be extremely hot to the touch. The composites wont heat soak and wont hardly have any temp change.
the carbon or fiberglass doesnt heat soak, but the resin softens with heat. if you want, you can source some heat-resistant resin.
or wrap with exhaust fiberglass / titanium wrap
I am shopping for after market intakes and I just don't understand why tubes and a filter cost over $300. Thanks for the idea.
+Bishop Cherry Coke I don't under stand either
Should do a temp test. To see if it can be used for charge pipe
just a comment on materials resistant to high temperatures.
Cork is very sturdy.
The Russians have used cork for decades as protective shields for their space capsules during reentry into the Earth's atmosphere.
In short, if cork could keep the Russian capsules intact, it withstands and thermally isolates the fresh air from the air around the engine of a car.
I have an idea on how to make a tube with cork incorporated, is a very old technique used in portugal, to join / glue materials.
A kind of sandwich plate .... cork +?
I like a MacGyver that thinks outside the box... What air filter setup are you using? Do you have a video of it yet? I've been scrolling through your videos, and have yet to find it? Can you lead me in the right direction?
I have the mold already made, my question is how do you get the mold out if it is metal? Thanks in advance. Great channel.
What I cant seem to find is the temperature rating on this material? Is is safe to have coming straight off a hot carburetor?
A year late but cast material is mostly plaster and fiberglass. Plaster is basically thin cement and can withstand high temps. Fiberglass generally melts at 1000°f
what i would be worried about is the heat + pressure cycling on that stuff. makes me want to get some CF tape and go through roughly the same process. things i would change are alternating the direction of the wrap(not sure if you do) and possibly going tape/sleeve/tape/sleeve.
1320crusier I have made these tubes several different ways over the years. Some with carbon fiber and some without. I have yet to make one fail even under pressure, heat cycling, race environment, daily driven...It may have a weakness but I have yet to find it in what I have used them for.
Now is there any truth to the surface of the inside of the plumbing being an issue if it’s not smooth? I was looking at doing one, I started at pvc… then esthetics worried me. Then u thought acrylic clear tubing. So if it’s comma be a plastic at least it’s different. Then.. carbon lol. And I was thinking to maintain smooth intervals,warp the mold in a thin gauge metal. It would give structure and smooth wall in the inside
couldn't you use fiberglass impregnated with gorilla glue, for large part making? maybe dip the cloth in resin then do the same thing... for hoods and stuff? After its in place you could spray it with water to activate the gorilla glue, then smooth out the bubbles as it drys?
Could you create the mold with pvc the wrap it? Be even cheaper than steel for those who either dont own or dont know how to operate, a welder.
+Nile Virus you could...sometimes its hard to get pvc to do what you need it to though
+The Fab Forums true. just thinking of an alternative
Definitely a viable alternative
A heat gun or filling PVC with hot sand makes it very pliable until it cools.
Buy an electricians heat wrap blanket.
This is crazy awesome 👌
I have a question about that cast material.. you said it takes 10 minutes to harden once wet, which makes it great for this sort of project.. but what happens if it gets wet after you've worked it into a tube and installed it on your car? say some freak water ingress or some hardcore river wading.
will it just turn to pulp again? in that case you could potentially collapse your tubing and develop a boost leak, or worst case block off your air intake completely or run casting tape through a turbo..
No once its hard its hard. Introducing it to water just activates the resin, once the resin hardens it won't be affected by water.
+The Fab Forums Good to know! Nice videos, lots to learn!
If the pipe gets wet will it soften? Or is it a single cure procedure? My main concern would be driving through a puddle and then getting mushy charge piping.
Thanks!!
-Zac
Fallible Reality Filter It is a single cure process. Once the resin has been activated by moisture it will harden and be cured for good.
man i saw all your videos thanks for all these good ideas and hope ill try to do them back in ksa , but i have a suggestion to include in metal ring on each side
Thanks...I plan to try some different things
Could you go over the tube with a regular fiberglass and resin?
You could.
Would this be a good material to make a cold air intake? I'm trying to come up with some ideas for my LS swap c3 Corvette.
yeah its always worked well for me
Wow never thought of that. Good idea
+Alex skrzypek thanks
thanks my friend I made one for my gt and it works perfectly .. thank u for the video u just saved a lot of $$$ yo thanks
awesome....glad I could help
Thank you!
I can't seem to find the link where this available. Could you post it again along with the part numbers for this wrap as well as the carbon fiber wrap.
Thanks !
This deserved to subscribe dude, keep it up
+dicky alexander thanks
cool idea, wish i knew this when I had my 72 camaro.
1down4up thanks
so the casting tape on the inside doesn't adversely affect airflow? let's say compared to the smoothness of the aluminum pipe? just curious. really would like to make some pipes for my car but i'll have to figure out how to add a MAF bung and PCV bung. thinking about two pieces epoxied together, then carbon fiber over everything.. Thanks in advance for your reply and keep it up the videos are great
no its is as smooth as an aluminum pipe. its take the finish of what ever you wrap it around
I do have a question. I'm trying to shorten the length from the throttle body to the filter some guy had it on his gt and it significantly increased throttle response. I'm just trying to do it. the throttle comes strait out, instead of taking that turn. anything would help thanks
How would you recommend to attach the air flow sensor for an air intake?
I have molded the mounts in on these in the past
Good idea Man i always say no. 2 Hondas. Because. Uf that. Require 2much. Time. 2Creating. Thanks. For u idea 👍
Jr.BLAST COATING 🚀 glad I could help
I wonder if it would be better though to find some kind of material to pour inside the tube you are trying to replicate, then pull it out and wrap that. It would obviously have to be something that would deform in order to pull out then go back to its original shape. I only say this because, correct me if I am wrong, but isn't your new part slightly larger than its original?
+Ryan Lockwood well it is initially but the material you take out when splitting it to take it off, brings the dia back down once reconnected.
I thought about using the expandable aluminum dryer vent type ducting and forming it to shape then fiberglassing.
+mopar340dave It would probably work...may not be very smooth though
+The Fab Forums This stuff is pretty rigid and smooth.
www.lowes.com/pd_433291-131-433291_1z0uauh__?productId=4566296&pl=1
+mopar340dave I could see that working
+The Fab Forums I dig your vids. You give me some great ideas.
+mopar340dave Awesome...thanks for watching
If I was you I would put a flange or a bead around each end so it creates a better seal for the silicone hosing
REPTIMAN1994 I could. The purpose of the video was to show others the technique so they could try different stuff.
It feels like if watching my cast being made again I’ve had 3 that exact blue
You mentioned a link? Don't see it in the description. Is there and actual retailer
Brian Schonewille Here is an active listing as of now: www.ebay.com/itm/231258286745?_trksid=p2060778.m1438.l2649&var=530485455653&ssPageName=STRK%3AMEBIDX%3AIT
Wow
Good info . Thanks
Any intrest in building 2 Carbon Fiber CAI tubes for my dual tb crossram intake on my LS7 65' Nova? I already have em built. They are a small 8" section into a simple 90* elbow. I can email pics so you could maybe send me back a qoute if interested.
Would this have a high enough heat tolerance that I can just clamp it right on my throttle body?
And how smooth is the inside? could you sand or resin it or something to make it smoother?
+Matt Lemmen yeah it can go right on you your TB and the inside is extremely smooth.
Hell yeah! That's awesome!
I used this to wrap my broken flexpipe u think thts safe?
So, did these ever get a pressure test? Not seeing anything in your videos
hay great video as always have you considered working in V-band clamps in between the tubing and carbon sleeve might be able to get a better seal and might be able to hold more pressure!!!!!! just a suggestion. keep up the good work
Geraint Lavis I have thought about it and would actually love them with vbands but not sure just yet how to attach them
Thanks for the message back Mr Fab while i was watching your most recent video i had a thought about the v-band idea and the one that kinda springs to mind would be with using the carbon sleeve and to place the coupling in between the molded tube and carbon sleeve i could go on for hour here but if you would like id be more then willing to show ideas I've had about this idea.
kind regards
Gee
Geraint Lavis shoot it to me in an email...thefabforums@gmail.com
TheFabForums.com What website Mr. Fab Forum is the composite site sold? Thx
The site is called makecarbonfiber.com, its currently not up but should back online next week sometime.
No clue if someone has asked yet or not, how about the product fiberfix? Its sold at like lowes. Wasnt sure if it would work or not, seems just like cast tape. Same price I think, just figured you wouldnt have to wait for it to be shipped. Any advice on that would be great. Thank you and awesome videos.
not sure... I will check it out
Sweet. Thanks!
Thanks for the insight
do you trust that casting tape in the intake system of a $10,000 engine? will the casting tape hold up to the high temperatures and vacuum of a turbo system?
+Paul Jenkins yeah I have never had any issues with it
How well does it hold heat melting burning state? Like to do something like this for an exhaust set up on a jetski.
not sure
Would this crack tightening it to turbo inlets?
how well would this hold up in the long run? would it ever flake from the inside in the long run?
Never had any issues with ir
Very cool approach.
Did you have to get larger couplers to install the tubes on the car? It's difficult to tell how much larger (diameter) the composite version is vs the aluminum part.
It depends on the size
@@Thefabforums Thanks. I considered cutting the ends off of my existing pipes, filling them with something like expanding foam, cutting the pipe off and using the filler as a mold for a piece that could be joined to the larger pipe. Or just getting a reducing coupler which sounds a lot more sane and efficient.
Wow....you are amazing,great work...can i make fiberglass air box??? is it possible to use only casting tape????
Thanks. It really depends on what it is your trying to make. Casting tape could probably do most of it.
The Fab Forums probably i wanna make something like your carbon fiber intake. The real reason to make this is to separate the air filter from the hot engine bay and make the cold intake air to stop into my air box.
What glue are u using to seal the first mold
What’s the heat range of this material? Does it have high heat soak into it? Great idea I’m gonna have to try this.
basically no heat soak.
The Fab Forums one more question what’s the life span of something like that? How often would one have to make a new mold?
it says it is porous in the Amazon description, am I missing something? why does air not leak out. don't they use this in hospital for broken bones because it's breathable?
bloody genius though if it works, great video tutorial, thanks :)
yeah it is porous but with enough layers it seals it up. I usually sand it and apply a coat of epoxy resin over the top
The Fab Forums yes great the resin will fix that! :)
I need to make my intake tubes oval for hood clearance. What method could I use to give me the correct shape?
Marcus Menge Oval mold.
Looks cool I'm sure but at that point it probably weighs more than an aluminum intake pipe??
actually way less and doesn't heat soak
How good is it with heat?
Is this type of tubing good for boost...like around 15 psi? I want to build custom piping for supercharger water/air aftercooler setup.
I have a video of some pressure testing one I made that was wrapped in carbon
The Fab Forums instead of using a carbon wrap, can I use something else to ensure there are no holes around the piping. Like an epoxy? If so what would you recommend?
Can you use the casting tape for intercooler pipeing or no
+NVdiamonds TM Not sure. I have made some that seem to be very strong but never tested under pressure
Any plans on the pressure test? Also would it be okay to paint these? I was thinking, do about 2 more wraps after the initial one that gets cut open then sanding and painting.
+Hot Rod Lincoln I have pressure test ones overlaid with a single layer of carbon but not just these by them selves. I have also sanded and painted them with great success.
The Fab Forums Okay, thanks for the reply. I might have a weekend project soon :)
no problem...anytime
What called is it?
at $11 a roll is this more cost affective than aluminum tubes and clamps?
Have no idea. The idea with this is not cost effectiveness, its about being lighter and having superior resistance to heat transfer compared to aluminum.
Good
nice!
How many layer of the casting tape do u recommend using?
one roll will make about 2 layers on most tubes. I would suggest at least two layers
Any results to share on how much psi these tubes can withstand
+IIFeeWeeII I have some videos on here where my carbon wrapped ones hold 30psi with no issues.
+The Fab Forums i think feewel was referring to the ones that are not carbon wrapped, just fibercasted ones
The link to buy the cast isn't working for me.
sorry. you can buy them on eBay....search casting tape
Same material they made my cast(broke foot) out of.
+Brian Jones yeah
nice bro thanks
+Naipaul Singh no problem
Is it stronger or lighter than the metal one?
+MrWipeli way lighter for sure
What is the tape that wrapped pipe
Its casting tape....link in the description
what limited I can use this tubing on psi
I have tested some covered in carbon up to 30 psi with no signs of failure
how would this hold up to gas? I have a 1975 kawasaki Kz 400s and my rubber carburetor manifolds are cracking, I can't seem to find any online to buy, so i thought maybe I could make my own. here is a link to my video that shows what i am talking about at 7:59 you can see where they are cracked just fast forward to 7:59 link below
th-cam.com/video/2cLj8qcrWWo/w-d-xo.html
1down4up I think it would hold up good to gas
very cool
thanks
just curious have u ever used chase saver? ur opinion if so?
I have not. Im not even sure I know what it is...
+The Fab Forums it's one of the best stuff for restoring vehicles and also monster liner made by the same company look it up when u got time. monster liner and Chase saver
I will take a look now
I can use this tubing for turbo on 6 psi
yup
+The Fab Forums can I use that for intake tubing on my honda?
Link for the carbon tubing?
amzn.to/2pXMSgy
could you not hold that below your waist
nope
Does anyone think the black carbon fiber intake at 6:13 looks like a giant cable auxiliary cord..lmao
were CAn i get,this WAP bro?
link in description
ok thanks
no prob
what grit sandpaper did u use
I think 600
Wat if the intake have pcv hole how would u go about that