In the pic below are the inlet side end tanks being crafted. What you're looking at is the main body of the design (similar to a vacuum cleaner attachment), which already has the high temp epoxy based interior shell hardened around a core of foam. The foam used is the stuff flourists use to arrange flowers. I bought a 6 pack block from an arts supply store here in the LA CA area called Michaels. It's very stiff, comes in brick size, small grained, but easily shaped with a knife and sandpaper. You can also glue two foam pieces together using a spray adhesive. Once the foam shape is finalized, I coated them with at least two layers of a high temp epoxy (JB Weld).

Once the epoxy is hardened, an initial layering of fiberglass matting w/resin goes over the epoxy shell. When that hardens you can then scoop and clean out the foam and smooth the interior as best you can. A very smooth inner surface is not necessary, but any obvious visual and textural flaws can be removed with the use of a rotary grinder and rough sandpaper. The reason for the epoxy shell is necessary, especially on the inlet side - to handle the heat better than the poly-styrene based resin. JB Weld is rated to withstand temps in excess of 500 degrees F.

You will also notice in other pictures that the custom end tanks are re-connected to the remaining IC end tank by using JB Weld first. In fact (and this is crucial), anywhere fiberglass resin touches the original IC end tank plastic, JB Weld is layered first, even if applied as a thin coat with your finger. Poly-styrene resin does not bond well to that particular plastic material, yet JB Weld is the perfect go between, bonding to both with equal strength. I used approximately three seperate coatings of fiberglass on all surfaces once the epoxy layer was in place and hardened. I also used both a rotary tool plus a heavy file to smooth out the surfaces between all layerings of both epoxy and fiberglass.

posted by 152.163.2...

• 9K IC to C900 pics - got em!, MS, Mon, 12 Jul 2004 21:14:46
  • great fabrication, damien, Tue, 13 Jul 2004 14:22:51
    • Re: great fabrication, MS, Tue, 13 Jul 2004 18:28:40
  • very resourceful! >>, Ram'89SPG, Tue, 13 Jul 2004 13:18:09
    • Re: very resourceful! (long), MS, Tue, 13 Jul 2004 18:04:55
  • additional comments II, MS, Tue, 13 Jul 2004 10:15:02
  • Right, so I have the pic situation sorted out. (link), MS, Tue, 13 Jul 2004 09:33:44
    • nice work man, jak , Tue, 13 Jul 2004 13:51:41
      • Another f-glass convert!, MS, Tue, 13 Jul 2004 18:31:02
  • looks like we have to log in to *your* account! n/m, Ram'89SPG, Tue, 13 Jul 2004 06:36:23
  • if password is required, MS, Mon, 12 Jul 2004 21:57:31
  • some additional comments, MS, Mon, 12 Jul 2004 21:50:46 <-- Viewing This Message
    • referenced pic, MS, Tue, 13 Jul 2004 09:39:17
    • No one can see the pics- asks for sign in & pass. NM, Taylor, Tue, 13 Jul 2004 06:47:33
  • isent working for me asks for a password? nm, jak , Mon, 12 Jul 2004 21:18:18

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