Re: what did you do in your garage today?
Since my Mustang eats brakes on track I finally decided it was time for ducting. I could have simply cut a 3" hole for inlets using a hole saw, but that really doesn't work well to force air into the tube. It works better if the air is "funneled" from a larger opening into a smaller one increasing the velocity. With that in mind, I'm using the plastic lower grill insert as a mold to utilize the empty spaces beside the openings for the radiator.
First up, the angle of the dangle so I can cut the exhaust tubing to use as part of the mold:
After a few attempts I found the correct angle. Here I'm test fitting it to be sure it's right:
I taped up the lower bumper insert to use as the mold:
I welded a couple of tabs on the tubing so I could attach it to the bumper insert:
I decided the foil tape would make a better mold release so I re-taped it and mounted the tubing:
I decided to use fleece as opposed to actual fiberglass mat. It can be stretched and forms a nice smooth compound curve with the aid of a few clips:
Now it was time for the wet work. I used polyester resin with MEKP catalyst and applied it to the fleece with a paint brush.
Once the resin had hardened I was able to pop it off the mold pretty easily:
Next I taped a line around the perimeter so I could cut the excess away using the Dremel:
With it all cleaned up it fits the bumper insert pefectly:
I decided it would be easier and look better to leave the honeycomb bars in place. I don't think theire area will block much of the air flow at all. I used a coping saw to cut through the plastic. It took quite a bit of time and effort, but it turned out well.
After cleaning everything up it was time to get the inlets mounted on the car along with the modified lower grill.
Driver's side rear view:
Passenger side rear view :
Passenger side front view :
Overall front view:
As you can see the inlets are almost invisible unless you know what you are looking for. I'm pretty happy with how it has turned out. Once I connect the high-temp 3" ducting it will be done and I'll will less than $150 in the project compared to a good off-the-shelf kit which ranges from $600-$1500 for the S197 Mustangs.