Custom 3D Printed Airbox Exploration

[swooshdave]

I recalled some conversations about air boxes like this one

I just got a new 3D printer (Bambu P1S) and I've been busy making stuff. As part of this I'm learning OnShape, which I'm finding more intuitive than Fusion, which I also tried. I'm finding that if I find practical (or even semi practical) projects it helps me learn the CAD app better.

The nice thing is that the printer is nearly flawless. I had a small printer many years ago (something like 2016) and I remember having to futz with the printer a lot. Now it's nearly pushing a button and waiting. And even though the printer is much, much faster it still takes time to print. The other thing that's changed is the materials you can print with. There is a huge variety with a variety of properties.

Where was I? Ah, projects. In thinking about fun projects I thought that a custom air box would be interesting.

The print area is approximately 256mm cubed so it will need to be made in sections.

I may just start by making some velocity stacks. Then go from there.

[po18guy]

With a LeMans fairing, one could conceivably run the intakes forward of the engine, maybe even into clean air. Expensive surgery though. 

[gstallons]

Keep us abreast on your progress !

[Bill Hagan]

 

Fascinating.  Impressive.

 

I’ll always be in the bleachers cheering on such things, as opposed to actually doing anything of the sort.  Still, I’m amazed at the potential.

 

My only direct connection with 3D printing so far is ordering some wind deflectors for the V85 that literally fill the void between the stanchions and tank.  That gap has been viewed as the cause of lots of wind turbulence and noise since the V85 appeared.  I found the fix pretty useless, but did admire the ides and execution.

 

Then, the Georgia Guzzi Guru, Wayne Orwig, made up a test set of front and rear turn signal stalks for my EV.  The OEM ones are infamous for corroding and falling apart.  That led to all sorts of MacGyver fixes of the popsicle stick splints, black electrical tape covers, and cable tie supports!  I wish I had a "before' pic handy.

 

Wayne's are grand ...

 

 

 

Best wishes from the snow-covered alps and steppes at the top of Virginia.

 

Bill

 

 

[swooshdave]

5 hours ago, gstallons said:

Keep us abreast on your progress !

I’m open to ideas! 

[swooshdave]

3 hours ago, Bill Hagan said:

 

Fascinating.  Impressive.

 

I’ll always be in the bleachers cheering on such things, as opposed to actually doing anything of the sort.  Still, I’m amazed at the potential.

 

My only direct connection with 3D printing so far is ordering some wind deflectors for the V85 that literally fill the void between the stanchions and tank.  That gap has been viewed as the cause of lots of wind turbulence and noise since the V85 appeared.  I found the fix pretty useless, but did admire the ides and execution.

 

Then, the Georgia Guzzi Guru, Wayne Orwig, made up a test set of front and rear turn signal stalks for my EV.  The OEM ones are infamous for corroding and falling apart.  That led to all sorts of MacGyver fixes of the popsicle stick splints, black electrical tape covers, and cable tie supports!  I wish I had a "before' pic handy.

 

Wayne's are grand ...

 

 

 

Best wishes from the snow-covered alps and steppes at the top of Virginia.

 

Bill

 

 

Nice! I’d be a little concerned that it might crack along the lamination lines but if it was printed with enough infill and thick walls it should be ok. Let us know how they do. 

[swooshdave]

Also if anyone can think of another part they’d want designed and tested let me know. 

[gstallons]

11 minutes ago, swooshdave said:

I’m open to ideas! 

$100 bills !

[swooshdave]

5 hours ago, gstallons said:

$100 bills !

As cheap as Guzzi people are you’ll be lucky to get $10 bills. 

[po18guy]

15 hours ago, swooshdave said:

I’m open to ideas! 

Since the EU clamps down on noise, intake noise is also targeted. A cross section of the passages in the lower box will determine if opening the upper will net an gain. I suppose you could pod filter the throttle bodies, but that would undoubtedly open Pandora's airbox. 

[gstallons]

My bike came  with K&N pods . after one ride they came off and the stock set-up went on .  whew , IDK how to describe the noise (not to be confused with a sound) but noise . I know I don't want to hear it again .

Edited Monday at 02:12 PM by gstallons

[swooshdave]

9 hours ago, gstallons said:

My bike came  with K&N pods . after one ride they came off and the stock set-up went on .  whew , IDK how to describe the noise (not to be confused with a sound) but noise . I know I don't want to hear it again .

Interesting. The velocity stack should sound even worse!

Speaking of velocity stacks I've watched a couple videos of people testing different stack designs and you can barely tell the difference on the dyno. I doubt you'd notice on the track. Even a Ramen cup did fine. Which is all to say that I probably can't mess this up too badly!

 

[audiomick]

What a delightfully silly car. I love it.

 

PS: for those interested in velocity stacks, this link was posted a while back on the german forum. Seems plausible to me.

http://www.profblairandassociates.com/pdfs/RET_Bellmouth_Sept.pdf

Edited Tuesday at 12:10 AM by audiomick

[swooshdave]

3 hours ago, audiomick said:

What a delightfully silly car. I love it.

 

PS: for those interested in velocity stacks, this link was posted a while back on the german forum. Seems plausible to me.

http://www.profblairandassociates.com/pdfs/RET_Bellmouth_Sept.pdf

I'm not convinced that CFD is the best indicator of real world performance. The YouTube videos of dyno runs with different stacks seems to support that. Although I'll concede that YouTube videos are pretty limited in the testing.

[swooshdave]

It was about a dozen clicks from a blank diagram to a printed piece. I just did this to see what it was like. About an hour to print out.

Next will be to start getting actual dimensions.

Edited Tuesday at 05:55 AM by swooshdave