Hanaldo's R34 Gt(T) Skyline Build

[Hanaldo]

Straight out of the mould, no cleaning up yet:

Bit of residue from my release agent taking the sheen off it, so will polish it up later. Doing the second half today.

[Manuel Kasko]

Awesome progress Martin

[75coupe]

Looks great!

How do you join the two halves?

[Hanaldo]

Looks great!

How do you join the two halves?

Structural epoxy adhesive. Put both halves back in the mould untrimmed, put the adhesive on the joint and then bolt the two halves of the mould together.

Have now infused the other half and filmed it this time, so for those that are interested, this is how I make each half:

[Hanaldo]

Structural epoxy adhesive. Put both halves back in the mould untrimmed, put the adhesive on the joint and then bolt the two halves of the mould together.

Have now infused the other half and filmed it this time, so for those that are interested, this is how I make each half:

Damn thing didn't post:

https://www.youtube.com/watch?v=V71k0VNi-vU&list=UUrTGbs2Wk4T5hblvKod-5zQ

Also forgot to add, the total weight of the first half untrimmed is a hefty 112 grams, and takes all of my 85kg's standing on it without any distortion.

[Hanaldo]

Second half is now also finished. Didn't take any photos, but it looks the same as the first half

Bought a - 10 Speedflow fitting for the breather return as well. Just waiting for my aluminium flat bar to arrive so I can bond it in, drill and tap it, then bond the two halves together and trim em up! Once I can fit it into the car, I'll work out my plumbing route for the bov return.

[Hanaldo]

Forgot to update this! I decided against the initial plan of bonding in a piece of 10mm aly flat bar as it proved too difficult to bend, instead decided to use a -10 Speedflow weld-on fitting which I scored and bonded in:

I placed some woven fibreglass rovings into those grooves to help distribute any load placed on the fitting, then layed a piece of fibreglass over the top followed by an additional two layers of carbon fibre. The fibreglass is an important layer to separate the carbon and the aluminium, preventing galvanic corrosion.

Then bonded the two halves together using structural epoxy adhesive:

Cleaned it up a bit, then polished:

[B-rice]

Dude that's looks nice. Is it going to be like the carbon fibre on motorbike exhausts. You can literally touch it even when the metal part is red hot.

[Hanaldo]

Oh yeh for sure. Carbon fibre is a very poor conductor of heat, which is another benefit of using it as an intake pipe over metal ones.

[B-rice]

You should definitely think of making more I'd be keen for one. Wonder why no one has thought of making carbon fibre intercooler pipes etc

[Hanaldo]

It has been done, many times, just not so much with Skylines which does surprise me a little bit. If you're interested, PM me, I would be happy to make more for anyone interested.

[Hanaldo]

Thought I'd post some photos of it all fitted up too:

Had to be careful not to strain my back putting it in Final weight including the fittings is 193 grams. To give you an idea, the original stainless 3" pipe (which was also 100mm shorter) weighed 775 grams.

[Manuel Kasko]

Amazing work mate! It looks great!

[Daleo]

Superb skills there, awesome end result.

Really like the integration of the dash fitting too, real pro touch.

[colourclassic]

Came out awesome! Does the bond between the AN fitting and the pipe have enough strength to tolerate the appropriate torquing loads?

As I mentioned before, if you make a 3" pipe to AFM, I'd definitely be up for one

[Hanaldo]

Thanks guys

The bond definitely has enough strength, that fitting isn't going anywhere. To be honest, I've probably completely over-engineered that. In case you're interested, the epoxy adhesive that I used, Araldite 2014, is a structural adhesive which by itself has a lap shear strength of 19Mpa, or 2755psi. Then in addition to that, I've used the fibreglass rovings in the grooves I cut into the fitting to help distribute the load, and the reinforcement (layer of fibreglass and double layer of carbon fibre) behind it will also help absorb and distribute load. Realistically, you would destroy the fitting well before you even overcame the strength of the adhesive let alone needed the laminate around it, but I like to be sure about these things

I've PM'd you by the way mate

Edited April 21, 2014 by Hanaldo

[B-rice]

Are you by anychance a materials engineer?

[Hanaldo]

I'm not, I just make sure I do my research and know what I need to know before doing something Composites are just infinitely interesting to me, so I never stop researching

[DCIEVE]

That's really impressive work, hats of to you.

[Mick_o]

Thats some nice work there Marty well done mate! Next job should be that horrible hot side pipe with 767866218355 bends in it

Edited April 21, 2014 by Mick_o