Stagea Air Deflector

[Sydneykid]

Next project on the Stagea is to make up an air deflector to go between the grill and the top of the radiator support panel. At the same time I want to make up a scoop to make sure the standard inlet to the air filter gets enough ambient air to feed the engine. It will bolt up to the radiator support panel and fit into the standard slot in the top of the Stagea grill.

First job was to make up a rough cardboard template, picture follows;

Then I will cut the 2mm aluminium sheet to the shape of the template. I will make it out of 2mm for a bit of extra rigidity, as it will only be supported/bolted at the rear and slot into the grill at the front.

More next installment:cheers:

[Jay95R33]

Wow, you've been busy with your Stagea.

I'll be keeping a keen eye on this thread.

Thanks yet again

J

[mcnamg]

ill be keen to see what this turns out like I cant wait for the pic

[gtst25]

Looks good SK

Would be good on my '33 - hmmm... materials - there's so many options - aluminium, carbon fibre, plastic.....

I'd like to see the end result!

[mcnamg]

best to use something that wont get too hot i suppose

[Sydneykid]

Hi guys, a little progress, this is the cut out alloy deflector. It is 2mm thick, which is a bit much. Around 1.5 mm would have been OK, but I didn't have a piece large enough. What's a few grams extra weight here or there compared to the weight of a Stagea?

The next step is a test fitting on the Stagea, which I will do this afternoon. Then I can cut out and bend the air feed (scoop) for the air filter inlet. I will post up some picures of that later on:cheers:

[Jay95R33]

Look'n good SK

J

[ICE12]

You will have to make two so that you can use it as a mould for the CF one, I'll be in on that SK.

Cheers ICE

[mcnamg]

yeah would look cool in carbon fibre you could even get even tricker and make it up so that is forms a really wide mouth for the air intake

[Sydneykid]

Ok did a quick test measure, cut out and bent the scoop for the air inlet to the standard snorkel......

The next step is to put some sides on the scoop, I will be using some right angle aluminium and then rivet it to the scoop. More pictures tomorrow:cheers:

[mcnamg]

looking good are you going to paint it?

[Sydneykid]

looking good are you going to paint it?

I haven't decided what to do. I would normally use the plastic coated aluminium sheet, so it doesn't get marked while you work. Then I would simply peal it off and it would polish up nice. This one is a bit marked, I might paint it, or stick some carbon film on it, or I might polish it with a pattern, I don't realy know yet:cheers:

[mcnamg]

what do you cut the metal with?

[Sydneykid]

what do you cut the metal with?

I have a number of cutting devices. I mostly used the band saw on this, for closed holes I used the jig saw, too lazy to use the hacksaw.

[Sydneykid]

The last steps before I fit it. First, pop rivet the sides to the scoop, then I polished it with Scotchbright to help hide the scratches;

I just have to drill the mounting holes and hopefully the next pictures of it will be when it is fitted to the Stagea.

[Terminal]

What about Anodising it? that's what we do with a lot of our aluminium plate pieces at Uni

[Sydneykid]

What about Anodising it? that's what we do with a lot of our aluminium plate pieces at Uni

My understanding is that, since anodising changes the surface colour of aluminium, any scratches that are in the original surface will still be visible through the anodising. So I could paint it, several coats would fill the scratches and it would like OK. Or, since this was the test one, I could just make another one now that I have the dimensions perfect. I would use pvc coated sheet this time so no marks from the workings. I don't know until I put it on how it will look, then I will decide.

[Jay95R33]

Making a template for it ?

[Sydneykid]

Making a template for it ?    

Would you like one?

[Jay95R33]

Would love one if it's possible. Even if it's just something rough it'd be great