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Post by roger32849 on Jul 30, 2014 1:11:20 GMT
I have been trying to bridge a couple of jobs here around the house as well as make appointments and go for an ocassional ride. I have both the left and right side molds prepped for sanding. I will be pursuing the same shape to fill in the triangular shape on both sides of the trike. I did look at the rectangular shaped intake scoop on the trike link you sent me Erik. It appears he did his design based on the same thing I did..... which was..... "Utilization of available space". Anyway, the molds are shaped and nearly ready. Let's see how it goes. So far I have $22.00 invested in foam and spray glue... the epoxy will be about $75.00 and the same for the cloth.... Forty quid seems pretty reasonable eh!!.?
Roger
Worcester, Massachusetts
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Post by erik on Aug 2, 2014 19:17:22 GMT
Hi Roger, No need to make moulds unless you are planning too build them in series. Just glass over the foam and remove the foam  |
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Post by roger32849 on Aug 2, 2014 21:51:38 GMT
I didn't know what to call the foam so just called it a mold. I intend to glass over the foam and remove it after a couple of layers of resin and material.
Thanks Erik
Roger
Worcester, Massachusetts
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Post by erik on Aug 3, 2014 6:46:52 GMT
a base model is called plug and the negative shape a mould where the final product can be moulded in.
You are using the lost foam method which is great for a single product. You may reconsider a few layers of cloth on top of it to keep best shape and after removal of the foam you can add reinforcement layers to the inside. If you make too many layers on the outside you may have to use a lot of putty to get a smooth finish.
br!
Erik
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Post by roger32849 on Aug 3, 2014 11:34:27 GMT
I have the foam all covered and mounted on a work stand. My plan is to apply 3 layers of material using a liquid epoxy polymer as the binder. I have it on some pretty good authority the one off "foam loss" method works very well especially when making a single product.
I am making a cover for the right side as well as the radiator scoop for the left. Even though the covers differ in shape, I feel some sort of symmetry is needed for a balanced look. The scoop itself will have an air turning vane incorporated in the design to direct all air straight into the radiator. The leading edge of the opening will be reinforced internally and then shaped and sanded smooth to insure strength and efficient movement of air. I am doing the right side first because it has been years since I have worked with fiberglass. The right side foam was easy to shape while the scoop took much longer. If there are mistakes, I want it to be an easy recovery.
I will be posting more pictures as I complete the pair.
Roger
Worcester, Massachusetts
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Post by roger32849 on Aug 5, 2014 12:54:54 GMT
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Post by erik on Aug 5, 2014 21:00:06 GMT
Not bad at all for a 1st timer! It'll be neat for sure!
Having some food for thoughts: you will have near fully enclosed the front part of the engine. Do you expect possible cooling/airflow issues later? Not sure if this cover will show negative side effects...
br!
Erik
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Post by roger32849 on Aug 7, 2014 1:57:32 GMT
Erik
The right side cover shown in the photos is not as important as the radiator scoop. I figured as long as I am making one.. I may as well make the other. If I experience negative effects then I make a few modifications on it or discard it altogether. The plug was easy to shape and the cost of manufacture can be recouped as a learning experience for the manufacture of the left side air scoop. The Burman scooter is nearly enclosed so I doubt I doubt if this cover will really cause an issue... (fingers crossed)
Roger
Worcester, Massachusetts
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Post by roger32849 on Aug 11, 2014 21:09:00 GMT
link   I started on the actual intake scoop yesterday. I took out the foam plug this morning and rough sanded and cut out intake opening. I am now making the turning vane and radiator mating surfaces so the scoop will fit air tight. By the way, the scoop in the photos has just been removed from the plug and has not been finished to any degree. Roger Worcester, Massachusetts
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Post by erik on Aug 14, 2014 9:02:11 GMT
I roger! They turned out pretty well! when painted you could make a mould of them and pull a few to earn back costs and make some business I'm looking forward to the inner design! grtz! Erik |
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Post by roger32849 on Aug 20, 2014 10:38:21 GMT
Erik
The inner design on the scoop is nearly completed I used fiberglass reinforced aluminum for the turning vane. I need to sculpt and smooth out the inside yet, then prime and paint. It should be done in a few more days. The epoxy I am using takes 24 hours to cure. I bought the slow curing harder to allow a longer working time, so I have to do things a piece at a time then wait for it to dry. Slow process for sure.
The turning vane inside the scoop is a curved arc rather than an angle. It "should" allow the air to flow smoothly into the scoop and then on into the radiator coil. The tolerances are quite tight but I allowed enough space to apply edge trim on the pieces that contact the radiator. Hopefully this will increase cooling efficiency.
The triangle shape fits well on my trike but not sure if it will fit other trikes. There may be differences in chassis manufacturing sizing/designs. I am new to all this fabrication and am not sure about mold making... but will consider it...
Roger
Worcester, Massachusetts
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Post by roger32849 on Aug 31, 2014 23:06:15 GMT
link  I managed to get the painting done yesterday and installed the scoop and side cover this morning. I want to compound the luster off the black to a semi gloss finish. I drove it around a bit (50 MPH or so) with the scoop attached. The coolant temperature stayed right at the midway point. It looks like the design is functional. Roger Worcester Massachusetts
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Post by roger32849 on Aug 31, 2014 23:15:06 GMT
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Post by roger32849 on Aug 31, 2014 23:17:01 GMT
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Post by roger32849 on Aug 31, 2014 23:18:38 GMT
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