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Advice required: Making complicated brake duct out of aluminium sheet


Hyperblade

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  • 2 weeks later...

So after some reflection on this, I decided to make my life easier by going for 2.5", while I could have fitted 3" in, it just wasn't worth the effort at the moment.

This allowed me to thicken up the outer edge of the plate, and move the air more inwards which is better. 

So plate ends up as this.

image.png.6b6dec476b18b6680d2a780cc9bbe827.png

For the ducts themselves, trying to get aluminium around them was proving too difficult for my skills, there was a couple of compound curves making life really difficult, even when I altered the ducting to be as simple as possible.

I looked at casting but they would have been minimum thickness of 4mm and $1000 odd.

I got a quote for 3d printing them in metal from https://craftcloud3d.com/ (min thickness 1mm)

image.png.9405c3d9676502c8172d8fea70911148.png

Actually not to badly priced $262nzd delivered for the 2 of them (in ali).

But the current plan is to take these moulds in PLA and just wrap them in fibreglass, then melt the moulds out (found a friend willing to try it).

image.png.a0ebd594c6f504b5ac3e546d98dbf66b.png

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