Firewall Forward - Last Updated 2/15/2010  
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  Mon Aug 3 20:09:27 2009 - I got the "good to glass" word from Don at AFP. So I spent some time on polishing the final shape. Namely, I smoothed out any bumps and glue risers. I also cleaned up the mating edges between the existing plenum and the future glass work. Ideally, I'll have a little lip on the inside that I'll be able to sand down to form a very nice transition. Also, I discovered that by using a Scotch-Bright pad, I can make very detailed improvements, compound curves, and blends with gentle rubs on this foam. I also did some research on mold release techniques and materials. I think what I'm going to do is apply long strips of Saran Wrap followed by either a very thin layer carnuba wax, Vaseline or even Pam (as in the spray on anti-stick stuff you use in the kitchen). I thought I read about the Pam option some time ago so I'm still researching it to make sure. When that is all done and ready to go, I'll be glassing this contraption in place.  Sun Aug 2 18:29:24 2009   Sat Aug 1 07:55:06 2009 - Don at Airflow Performance was kind enough to provide some great feedback on this plenum design. He recommended that the inside corner have a 'D' profile. So I did that this AM. He did not have any concerns about the outside corner. The horizontal mark at the end of snorkel marks the very edge of the AFP server inlet.   Thu Jul 30 19:51:17 2009 - Take two! It was obvious that during the 1st run, I used way to much "Great Stuff". What can I say, it's interesting stuff. Anyways, as it cured, it expanded. And as it expanded, it moved my plug about 1/2" from the inlet of the AFP servo. Live and learn. So I tore out the old "Great Stuff" to free the plug and started anew. This time with a little muscle to hold things in place and less "Great Stuff". I did discover that the "green stuff" does not dissolve in acetone nor does "Great Stuff" _after_ it cures.  Tue Jul 28 16:39:45 2009 - Final throws of shaping. I needed a way to fasten the foam to the snorkel so I bonded the two with "Great Stuff". When this sets, I'll hopefully be able to remove the snorkel, do any final shaping, apply some mold release then start laying up layers of fibreglass. I'll then dig out the foam and sand for a smooth inside finish. Anyways, that is the plan.  
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Sat Aug 1 07:55:06 2009 - Don at Airflow Performance was kind enough to provide some great feedback on this plenum design. He recommended that the inside corner have a 'D' profile. So I did that this AM. He did not have any concerns about the outside corner. The horizontal mark at the end of snorkel marks the very edge of the AFP server inlet.

Sat Aug 1 07:55:06 2009 - Don at Airflow Performance was kind enough to provide some great feedback on this plenum design. He recommended that the inside corner have a 'D' profile. So I did that this AM. He did not have any concerns about the outside corner. The horizontal mark at the end of snorkel marks the very edge of the AFP server inlet.

Capture date : Sat Aug 1 07:55:06 2009

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