Fabrications

[XTR2Turbo]

I am interestes in fabricating a custom ECU cover for my car.

I had thought of Alluminimum but would now prefer fibre glass.

I would appreciate any tips or info sources.  Best way to make plug, sources of raw glass material etc

Thanks

David

[Chris Elworthy]

Thinking of doing the same myself

Found this site when searching last week

See for yourself

I'm going to try the foam route to lay up a diffuser - don't hold your breath waiting for the pics.

[timd]

Make the plug out of anything really so long as it gets a really good surface finish and lots of coats of wax. MDF is fine if sealed and waxed up - or proper modelling clay like I use works well too.

Don't forget to work out which side you want the gelcoat finish to be on - if you're making a plug then you'll probably have to take a mold off that and then layup the part in this mold.. This is normally the simplest way as it's much easier to smooth/polish a male part than a female one (no comments please! ) - but be aware of the extra GRP materials needed when ordering.

There's some guff on my site about making the aeroscreen molds which might help. Click here then click on "Aeroscreen" for loads of tedious pics..

From experience the most important thing is the finish of the mold/plug. You need to be able to see your face in it - so go through all the grades of wet and dry (used wet) up to 1500grit then t-cut, and then 5-10 coats of wax to act as a release agent and you'll be laughing.

Also make sure you give yourself a generous draft angle on the sides of the plug or the mold will clamp itself on as it cures and shrinks. (subsequent parts will be ok as they will shrink away from the mold - assuming male plug and female mold..)

Wait until gelcoat has gone almost dry to touch (but at least 4hours) before laying up on it of it will "wrinkle" and look crap.

Dunno where you're based but I get all my GRP and Carbon supplies from:

Marplas Ltd

Martineau Lane

Norwich

NR1 2HU  

(01603) 667303

Really helpful place and they also do mailorder if required.

Hope there's something useful in these ramblings - drop me a mail if you want to know anything else.

[Turbowestie.co.uk]

sources of raw glass material etc

A boat chandler is a good place to get your materials from, i have used them in the past and found them to be very cheap and of high quality.

[Paul Hurdsfield - Joint Manchester AO]

sources of raw glass material etc

A boat chandler is a good place to get your materials from, i have used them in the past and found them to be very cheap and of high quality.

Or Scott Bader, they have branches all over the country, my local one is in Stockport, just look in yellow pages or do a google search  

They supply Westfield, if you look on the back of your f/g parts you will see a label with mould ref, laminators initials and a code number usually starting with SB then 3 numbers thats a Scott Bader reference  

[7SE]

I am interestes in fabricating a custom ECU cover for my car

Have you thought of buying something from the Maplin or RS catalogue?

[Turbowestie.co.uk]

Depending on your ECU, it may require some airflow for cooling, if it has ignition amps inside it will get warm.

I have had engines on the testbed doing high speed durability cut out due to high ECU temps.......just a thought.

[XTR2Turbo]

Thanks all.

It's a DTA ECU.  I have tried Maplins but nothing quite right.

David

[Chris Elworthy]

I have tried Maplins but nothing quite right.

'Ello campers....Hi De Hi