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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Tue, Jan-16-2018, 06:47:28 PM   #11
HassanEido
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Default Re: My Custom CF Airbox Journey Begins

Quote:
Originally Posted by M3_Pilot View Post
This is awesome! Do you think this will cost as much as buying one?
Nah...a used stock box, 6 yards of cf cloth and some epoxy resin... not even close a couple of weekends to spare and some skill is required no doubt
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Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10
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Old Tue, Jan-16-2018, 06:52:11 PM   #12
TboneM3
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Default Re: My Custom CF Airbox Journey Begins

The problem is though, without an autoclave and pre-preg, can you make a box that is as loud (stiff) as OE or Evolve or Karbonious?

I'm all for saving $ and having fun with a project trust me, but with this particular mod, IMO, sound is everything.
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/// 2004 SilberGrau M3 · Coupe · 6MT · slicktop · manual seats · zero options · JOURNAL
-NA S54-


·Evolve-R Alpha N · Evolve CSL CF Airbox · Eventuri Scoop · Supersprint V1 stepped 63mm · SS V1 S pipe 63mm + 200 cell HFC · OE sect 2 60mm · SS Sport 60mm
·Besian · RE pullies/fan delete · WPC rod bearings · GroundControl S/A (Koni/Eibach 440/525) + tall RSMs · TMS Camber & Subframe plates · SPC Adj alloy rear camber arms
·RE Trans Mounts · AKG poly SUB/DIFF 95a · SDW RTAB · Weighted ///M knob + UUC DSSR + delrin carrier bush · OE CSL trunk · APEX 75mm Studs
·Sportline 8S 18"x8.5/9.5" · MPSS 245/275 · Brembo 996 36/40 345mm CSL Textar FF & 28/30 328mm CSL ATE "D738" FF · CM brackets & ss/teflon lines
·Pioneer DEH-80PRS · Eclipse PA5422 · CDT HD-6 + WS-100i · CDT EX-530 · 8" Kicker

DD/Beater: 1999 Civic LX - Kenwood x998 · PPI 1600.4 · CDT HD-6 + HD-100 · CDT EX-530 · DVC 10"
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Old Tue, Jan-16-2018, 07:27:07 PM   #13
HassanEido
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Default Re: My Custom CF Airbox Journey Begins

Quote:
Originally Posted by TboneM3 View Post
The problem is though, without an autoclave and pre-preg, can you make a box that is as loud (stiff) as OE or Evolve or Karbonious?

I'm all for saving $ and having fun with a project trust me, but with this particular mod, IMO, sound is everything.
Oh sure... Autoclave is for curing prepreg resin.. it's heat activated and thats why it's used. There's a multitude of hardners that cure at room temperature, depends on what chemical trigger is used, and stiffness has nothing to do with it.
Strength in cf is a function of fiber orientation(well among other factors) but mostly a cf sheet will be stiff across its fiber orientation, so a 0-90 twill weave will withstand twisting forces and a 45 degree orientation (left and right) will add compression resistance to the middle of the sheet. You can design ur cf to have strength in the direction of force applied, or make it all round stiff by clocking ur fiber or using biaxial sheets which has fibers oriented in the two axis for strength. This type of sheet is usually used below the top cosmetic one.
The thing that people confuse is that wet lay (not to be confused with vaccum infusion) usually has more resin in it, because u do not realy control how much resin is used,to an extent u can by weighing equal parts of cf and resin (common good practice). where as vaccum infusion will have only a minimal amount of resin in the composite, so a part made with vaccum infusion will be lighter.. but not by much. But even vaccum infusion does not require an autoclave at all only heat curing resin needs one, thats prepreg carbon.. coz in that case heat is the catalyst.
Anyways, hope u guys enjoy this project as much as I do, been planning this for a long time
Karbonious and evolve use 3d printing and stuff I dont have access to, to make their boxes pieces of art, I'm just making my own the old fashioned way
__________________

Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10

Last edited by HassanEido; Tue, Jan-16-2018 at 07:32:28 PM.
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Old Tue, Jan-16-2018, 07:35:33 PM   #14
HassanEido
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Default Re: My Custom CF Airbox Journey Begins

Here's a video explaining a few things:
__________________

Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10
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Old Tue, Jan-16-2018, 07:42:34 PM   #15
KhanArt
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Default Re: My Custom CF Airbox Journey Begins

Will be following Hassan
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Old Tue, Jan-16-2018, 08:40:52 PM   #16
M3_Pilot
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Default Re: My Custom CF Airbox Journey Begins

Quote:
Originally Posted by HassanEido View Post
Oh sure... Autoclave is for curing prepreg resin.. it's heat activated and thats why it's used. There's a multitude of hardners that cure at room temperature, depends on what chemical trigger is used, and stiffness has nothing to do with it.
Strength in cf is a function of fiber orientation(well among other factors) but mostly a cf sheet will be stiff across its fiber orientation, so a 0-90 twill weave will withstand twisting forces and a 45 degree orientation (left and right) will add compression resistance to the middle of the sheet. You can design ur cf to have strength in the direction of force applied, or make it all round stiff by clocking ur fiber or using biaxial sheets which has fibers oriented in the two axis for strength. This type of sheet is usually used below the top cosmetic one.
The thing that people confuse is that wet lay (not to be confused with vaccum infusion) usually has more resin in it, because u do not realy control how much resin is used,to an extent u can by weighing equal parts of cf and resin (common good practice). where as vaccum infusion will have only a minimal amount of resin in the composite, so a part made with vaccum infusion will be lighter.. but not by much. But even vaccum infusion does not require an autoclave at all only heat curing resin needs one, thats prepreg carbon.. coz in that case heat is the catalyst.
Anyways, hope u guys enjoy this project as much as I do, been planning this for a long time
Karbonious and evolve use 3d printing and stuff I dont have access to, to make their boxes pieces of art, I'm just making my own the old fashioned way
*Ahem* Which online course did you take?
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Old Tue, Jan-16-2018, 09:04:31 PM   #17
HassanEido
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Default Re: My Custom CF Airbox Journey Begins

Quote:
Originally Posted by M3_Pilot View Post
*Ahem* Which online course did you take?
Well , not gonna advertise anyone. But there's plenty .
Also many tutorial videos on youtube if you like to watch and learn
Just to be clear, I'm not selling this to anyone, so my credentials dont really matter lol, just sharing with you guys my custom projects as usual.
__________________

Mods:
-Custom CF airbox
-SSV2 catless headers, Custom 2.5" dual sec1, Custom sec2 2.5" dual with e9xM X pipe, SuperSprint Race inspired custom section 3..
-Cat Cams 280 272.
-Custom dyno tune
-Tms pulleys and electric fan conversion
364.1 whp 287.8 wtq

Custom exhaust thread and dyno http://m3forum.net/m3forum/showthread.php?t=569086
Cams thread and dyno http://m3forum.net/m3forum/showthread.php?t=554439
Custom cf airbox thread http://m3forum.net/m3forum/showthread.php?t=595180
Why not to use after market bearings with surfacetreatments and /or increased clearance
http://www.m3forum.net/m3forum/showp...4&postcount=10
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Old Tue, Jan-16-2018, 10:25:17 PM   #18
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Default Re: My Custom CF Airbox Journey Begins

There’s a guy in Germany that makes an exact replica plastic M3 trumpet (with mounting rings) in bulk that are the same as oem for €4 each trump. The quality looks really good so if you want to buy those instead of cutting an airbox open to extract the trumpets PM me and I’ll show you where to get them from.

Good luck with the project!
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Old Tue, Jan-16-2018, 10:39:47 PM   #19
grannyknot
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Default Re: My Custom CF Airbox Journey Begins

Quote:
Originally Posted by HassanEido View Post
Well , not gonna advertise anyone. But there's plenty .
Also many tutorial videos on youtube if you like to watch and learn
Just to be clear, I'm not selling this to anyone, so my credentials dont really matter lol, just sharing with you guys my custom projects as usual.
Fantastic, really looking forward to watching your progress.
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Old Tue, Jan-16-2018, 10:45:01 PM   #20
Toxic0n
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Default Re: My Custom CF Airbox Journey Begins

Very cool! In for updates. I would love to do something like, especially considering I have a 3d printer. They even make CF filament but it's probably not nearly as strong as pure CF:

https://www.3dxtech.com/carbonx-carb...ting-filament/
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Discussing My Custom CF Airbox Journey Begins in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)