Custom Carbon Fiber Fabrication

[SoFresh]

Ok... so I'm sort of tired of the lack of aftermarket parts for the A3... especially the lack of CF parts, add-ons, etc. There are a few out there, such as from OSIR... etc, however the $500+++ price tags are not worth it unless you got some extra cheese layin around. Therefore... I have decided to buy a few yards of CF and make the following:

-CF engine cover (custom fitted for neuspeed intake)
-CF air intake box
-Some other CF engine dress up accessories
-CF front lower fog light grill insert/air ducts...

So ill keep you guys updated and post tons of pics, since I know everyone rather look at pics

So... that is all, I know some will be pissed cause they clicked this thread and there were no pics, you'll have to wait for the materials to arrive, as for now, all I'll be creating are molds, templates, etc.

[fusionx]

sounds awesome if you can pull it off!

how much does each yard of CF go for? and how hard is it to wrap stuff with?

[SoFresh]

sounds awesome if you can pull it off!

how much does each yard of CF go for? and how hard is it to wrap stuff with?

CF depends on the quality, weave pattern, and if you want it mixed with graphite, or kevlar, or a color weave, etc. Rangs from 50"x12" usually for $30 and upwards + shipping. Wrapping is failry easy, however I was going to actually make CF parts, not just wrap parts.

I've done quite a few fiberglass speaker boxes, and body parts before, so it shouldn't be too hard. I am trying to source some heat resistant clear resin to use so it doesnt discolor from the heat of the engine. Also can't decide if I want to use a gloss clear finish or the matte clear finish for a dry look....

[fusionx]

Oh interesting


Id go with the gloss look, the dry look just looks like matte grey

[jrock]

Theres a seller on ebay who sells MAX CLR which worked pretty good for me. I have not done any engine parts yet so i can't tell you how well it responds to heat. However, some other ppl have and i have not heard any complaints.

[SoFresh]

Theres a seller on ebay who sells MAX CLR which worked pretty good for me. I have not done any engine parts yet so i can't tell you how well it responds to heat. However, some other ppl have and i have not heard any complaints.

Thanks I had seen his stuff on there, seems like a reasonable price too. I just sent him a message asking how well it holds up to heat and discoloration due from heat.

[jrock]

You should also pm 4inchMAF to see how his engine parts are holding up

http://www.audizine.com/forum/showthread.php?t=255427

[SoFresh]

You should also pm 4inchMAF to see how his engine parts are holding up

http://www.audizine.com/forum/showthread.php?t=255427

Awesome, thanks, I sent him a PM. I know he hasnt been using his parts very long, but still asked about the coloration/discoloration.

[jrock]

Word Let me know how it works out cuz i am going to start some more cf projects soon too.

[SoFresh]

I had some time after work today to start some mockups of the intake heat shield... didn't get to finish it, however here are some progress pics:



Keep in mind that where the intake pipe comes through it will be a hole cutout, not a square, I just did that for ease of fitting.



Again, it will be just a hole cutout for the intake pipe.



The radiator hose is in the way... so i'll have to figure out some shapes to go around that (I could modify it, but would be too much of a hassle IMO.



Had a couple beers in the process...






There isn't a lot of room for a full on box, I want to bring a duct up from the driver's side fog light housing up through the hole below the dirver's side rear of the headlight, and make it so it can connect via hose clamp to the intake heatshield/box. Decided to remove battery because the battery trey has a huge chunk of plastic that comes out and blocks where I want my intake box to rest on.





I am researching where the new 2008 Audi TT's battery is placed, because they have a similar layout as we do, minus the battery in this location, I bet its in the trunk, waiting on confirmation from the TT form. This would be nice, cause then I could order the TT parts for an OEM look on the relocation of the battery if I decide to go that route to free up some engine compartment space...

[sc_flaw]

Looks Good, Keep us posted

[krazyboi]

Looks good! Let us know how it goes. Did you do a custom speaker box for the A3 yet? I want a setup, but I know it can get costly.

Is fiberglass easy to work/play with? Or is it messy and time consuming? I guess a combo of all the above.

[terje_77]

looking good

[SoFresh]

Looks good! Let us know how it goes. Did you do a custom speaker box for the A3 yet? I want a setup, but I know it can get costly.

Is fiberglass easy to work/play with? Or is it messy and time consuming? I guess a combo of all the above.

No I havent done a custom box for the A3 yet, I debate doing one cause I like to use the trunk space, and I love bass yet I feel like the stock system is fine (mainly dont want to put in electronics to keep people from breaking in and stealing them)

Its not too costly to make your own custom fiberglass box, nor really time consuming unless you want to paint it, then you'll need to sand it until its smooth, and use body filler, etc. (gets super heavy) You could always do fiberglass then wrap in vinyl or carpet or suede, or even carbon like fabric to save time on all the sanding making it less time consuming. Fiberglass can be messy, but you'll eventually pick up a routine so its not all that bad.

[SoFresh]

Ok, so I was doing some more research on this project, and noticed that the new 08 Audi TTs have the battery located standard rather than up in the engine compartment, otherwise their engine compartment would be the same as ours:



2008 Audi TT engine bay: (Does anyone know where their washer fluid reservoir is located...?)



So, I am not sure if I want to relocate the battery into the trunk like the TT to free up some space in the engine bay or just make a CF battery box for in the engine bay....

[the4ringer]

pm iModTTS

[secnd2no1]

a cardboard box will do?

[littlewhite]

thought you are busy with work and stopping by hundreds of places? Not worth doing it man

[SoFresh]

thought you are busy with work and stopping by hundreds of places? Not worth doing it man

haha, yea, Ive been pretty busy with traveling for work. I found some materials I want to use, never heard back from the vendor via email. I ordered some stuff but never got the bill.... assuming theyre out of stock???

[UberA3]

You are just going to wrap cardboard? Not vacuum form it in a mold like the standard process. I doubt this will work but keep updating.

[SoFresh]

wow guys... didnt realize I needed to explain it that far in depth... NO I WILL NOT BE WRAPPING CARBON FIBER!!!!!

It will be solid Carbon Fiber/Kevlar!!!

Cardboard was used to form the shape/mold.

[cerfus]

You are just going to wrap cardboard? Not vacuum form it in a mold like the standard process. I doubt this will work but keep updating.

lol are you retarded? (just kidding), theyre templates, he says so in his post.

..start some mockups of the intake heat shield..

[gq9]

wow guys... didnt realize I needed to explain it that far in depth... NO I WILL NOT BE WRAPPING CARBON FIBER!!!!!

It will be solid Carbon Fiber/Kevlar!!!

Cardboard was used to form the shape/mold.

lmfao. thought the cardboard could do it as well man...looked so...convincing. hahahhaa

[SoFresh]

lmfao. thought the cardboard could do it as well man...looked so...convincing. hahahhaa

Maybe ill mix it up with some scotch tape and aluminum foil... maybe color it with some scratch and sniff markers too!!

hahaha

[the4ringer]

i say wrap it in go-fast stickers. think of the HP you'll get!

[krazyboi]

Maybe ill mix it up with some scotch tape and aluminum foil... maybe color it with some scratch and sniff markers too!!

hahaha

duct tape will work better then scotch. also gives color

[SoFresh]

duct tape will work better then scotch. also gives color

haha, but I already got some duct tape in there!! Maybe I need the CF duct tape lol

[UberA3]

lol are you retarded? (just kidding), theyre templates, he says so in his post.

Missed that part

[fusionx]

hey....how about keep the cardboard and get some of that carbon fiber tape at pep boys :)

[TheMadDutchman]

Ok, so I was doing some more research on this project, and noticed that the new 08 Audi TTs have the battery located standard rather than up in the engine compartment, otherwise their engine compartment would be the same as ours:



2008 Audi TT engine bay: (Does anyone know where their washer fluid reservoir is located...?)



So, I am not sure if I want to relocate the battery into the trunk like the TT to free up some space in the engine bay or just make a CF battery box for in the engine bay....

I have HP Autowerks lightweight battery kit in my A3. Nice aluminum bracket with the optional carbon Braille battery. As you can see it frees up some room and shaves some weight too.
Contact: [email protected]





contact: [email protected]