52 Suburban project thread

[tygaboy]

OK, let's get into some composite fabrication! I want to start with a custom carbon fiber intake cover. Here's the motor in stock form. "Turbo Power" just screams for everyone to stand back! In this 5400 lb truck, I think we're all pretty safe. At least while it's in stock form.

[tygaboy]

Pop the cover off and we're left with a motor that looks like it asked for a "Flat Top" when it last went to the barber shop...
Kinda cool about turbo diesels that they really don't care (within reason) about the shape or length of the intake track. I forgot to mention that I'll also be adding an intercooler to reduce the intake charge temp. Not sure if it'll be air/air or air/liquid but big improvements to be had going forward.

[tygaboy]

FAVOR PLEASE? Can someone measure the width of the inside of their 47-54 engine compartment about where it looks like the turbo will sit? Maybe a series of measurements of width starting at the engine/trans surface coming forward?
My concern is that the turbo will interfere with the inner fender and I'm just trying to get an idea of how much. Not too big an issue, I hope, in that I can either mod the inner fender or perhaps build a riser to lift the turbo. Lord knows we have enough height under the hoods of these things.
I also have to consider the size of radiator I'll need to cool this thing.

[Jebb1978]

I am liking the direction you are heading. This is going to be a very unique burb.

[Igotachevyor2]

looks great

[earl87gta]

I have the diesel in a 68 burb thats going to be a cool cover. I was thinking of going with an aftermarket style intake that would look cleaner.

[tygaboy]

Got a bit of progress made on the engine cover. Worked the shape a bit to make the "Turbo Power" stand out a little more. I also have a "Suburban" badge (see earlier in this thread) that I think I'll bond onto this as well.
Anyway, I layed up the mold and should have it out and ready for production part layup this coming weekend.

[earl87gta]

I didnt think you were going to keep the turbo power . I looking good cant wait to see the finished product. I need to lern how to lay carbon Ive done a lot of Fiber glass is it close to the same?

[tygaboy]

Originally Posted by earl87gta

I didnt think you were going to keep the turbo power . I looking good cant wait to see the finished product. I need to lern how to lay carbon Ive done a lot of Fiber glass is it close to the same?

Until you start getting into pre-preg carbon, it's essentially identical to working with fiberglass. The fun comes when laying up the production parts in that the carbon fabric is there for all to see - why use carbon fiber if you're not going to show it off? - so care must be taken to postion the weave in the direction you want, seams are all visible so planning where each piece goes is important. And depending on the weave, the fabric 'moves around' more than 'glass and it can be tricky to get the look you really want. And I don't know if I'll vacuum bag this or not...

Here's a link to a carbon fiber motorcycle gas tank I built. It goes through every step of the process. If you're interested in composite fab, it's worth a read.

http://www.bayarearidersforum.com/fo...d.php?t=145975

If you do a search on that forum for my user name, you'll see build threads for other stuff I've made.

I'm only going to document the major progress as I build this engine cover. Once I start on the interior, I'll provide more detail.

[tygaboy]

One 6.5 Turbo Diesel engine cover mold, ready for use. This is a "make one part and toss it" mold so it's pretty flimsy. But it's all I need - no use wasting material on something that's essentially disposable. Plus, I could safely make a couple/few parts with it, if I needed to. Just have to be a bit more careful.

[tygaboy]

And we have 'vette brackets partially installed! It's very cool to see it coming together. The folks doing the work (I'm not ready to trust my welding for anything structural) tell me they are really impressed with the Flat Out components.
Also have the Progressive X-Member and full frame boxing plates on the way.
Getting there...

[tygaboy]

Got a chance to start the lay up on the engine cover. I'm going with a "piece at a time" technique. I apply the epoxy to the small areas I want to work on, let it get tacky to the point that I can touch it and leave a finger print but get none on my finger. Then I can press the pieces into place. This first layer of epoxy serves as a sort of gel coat and helps the visible layer of carbon stick and prevent bridging, air bubbles, etc. Tomorrow I'll lay up the sides and add the rest of the layers to get the thickness I want. Should have a nice carbon fiber engine cover by Sunday afternoon!

[earl87gta]

Man that is sweet. I think I need to invest in some carbon next time I make a part. I have a mold of a 67 gauge pannel maybe ill try to lay down carbon to see how it looks.
Im suprized you dont notice the seams. I figured you would be able to see them more like on the back side pic.
Looks great I cant wait to see what else you have planned.

[Igotachevyor2]

the carbon fiber looks great. how much heat can it withstand?

[tygaboy]

Originally Posted by Igotachevyor2

the carbon fiber looks great. how much heat can it withstand?

I've built heat shields for motorcyle applications with no issues. Not sure about this one as it bolts right to the turbo housing. I'm going to run this part as a test prototype to be sure this epoxy (West Systems) will last. There are other, higher temp tolerant epoxies and I may have to move to a different product. Let's see how the test goes!

Im suprized you dont notice the seams. I figured you would be able to see them more like on the back side pic.

There are no visible seams since the outer, visible layer of carbon because it went in as a single piece. I piece in the rest of the layers as it's more cost effective vs the waste that's created laying in a single piece. It's hard to describe but you have to use more fabric when you go for that "no seams" look on a part that has lots of compound curves. So, the inside has lots of seams, the outside has none!

[tygaboy]

It rolls! Just mocked up at this point, pending final approval of wheel placement in the fender wells. But how cool to see it with some wheels on.

It's on the lift as there just isn't room with all the other activity. I'll get some better pics once it's back down. And no promises on these wheels - 20 x 10.5 and 18 x 8.5 - as they may well not fit under the body - but I like the size and look.
Frame boxing and X-member installation is next.

[paul5663]

Cool to see some progress. Looks great so far! Keep posting!
Paul
http://67-72chevytrucks.com/vboard/s...d.php?t=229882

[paul5663]

By the way, are you using the stock corvette rack? I just installed my motor (350) and clearing the vette rack lines (the 2 on top) is a major challenge at best. I ended up placing the motor where the lines fit just between the harmonic balancer and the block. There is BARELY enough room there. That corvette rack is mounted really high on the crossmember. I compared it to my buddy's 49 w/ a TCI MII front end and he has a ton more clearance. Good luck.
Paul
http://67-72chevytrucks.com/vboard/s...d.php?t=229882

[chrislehr]

this needs an update!

[Big Burb]

I have a feeling chrislehr wants an update from tygaboy. Mine is the machinist didn't follow instructions and sent home a block with a crack I didn't find until final assembly. I now have a very expensive and impressive paper weight. It's very hard to find a good "67 292 L6 bare block!

[HarrolLS1]

Oh! also watched your "lap of shame" video.. No shame there... some people sit on the sidelines and some people are IN the game.