Carbon Wrapping Project: e46 HPF AA M3 Engine Parts

[Nachos23]

Hey;

Just started a new project; an AA Supercharged e46 HPF M3!! Doing many of the engine pieces; including intake manifold!!.

Just started, so only a couple wrapped so far, but I've cut the cloth and prepped the remaining pieces. So after the Superbowl tonight I might wrap another couple of pieces.

I'm doing this in a 1x1 weave which I'm really enjoying. The tighter 1x1 weave provides a more "sturdy" cloth which feels slightly thicker and I'm finding quite nice to wrap with.

His engine bay before the wrapping project:


Below are the parts I'm going to be wrapping being prepped:








First wrapped parts pictures:






I'll be posting new pictures as I wrap new pieces through to completion. Will also post installed pictures as well to complete thread...... :

[witeshark]

Sweet project!

[Nachos23]

[Minez210]

good stuff bro. looking forward to ur progress

[k.sidlosky]

I've got a couple questions. I work with carbon fiber a lot and was just wondering how you manage to spread the resin to harden the carbon fiber? Also what resin are you using? 9396? How do you get it so tight? Do you vacuum bag it or just let it sit out?

[Nachos23]

Originally Posted by k.sidlosky

I've got a couple questions. I work with carbon fiber a lot and was just wondering how you manage to spread the resin to harden the carbon fiber? Also what resin are you using? 9396? How do you get it so tight? Do you vacuum bag it or just let it sit out?

Hey; fun stuff isn't it? I use 1.5" brushes to apply resin to part and to apply first top coat. Just tried the foam brushes and think I'm going to be using them for subsequent coats. I then use West System rollers on a short roller 3-4") to embed the resin into the fabric. The same West system rollers can use cut into quarters to act as a squeegie to remove excess resin from each application.

So tight? Experience of over 450 parts now! No Vacuum bagging because you lose control of fabric once pressure is applied and I want to control the fabric as it wraps around bends, etc. Used to use alot of tape to hold fabric while drying, but now I pretty much let it cure without; but only recently have I developed the skills to do that. The pictures I posted are the part basically an hour after applying the fabric. It was completely wet and the resin not cured at all.....

Resin and Hardener is West Systems products.

[Nachos23]

Time for an update. Urgent family matters took me away from wrapping for a few days. Expect updates to Mercedes set and finishing the RHD e46 coupe set as well in next couple of days. Just m3 updates for the moment:

Intake Manifold - Part 1; Intake Tubes:




ECU Cover




M3 Valve Cover






Part 2 of Intake Manifold tomorrow and finish 2 remaining pieces: Xenon cover and Secondary Air pump cover......

[witeshark]

Very nice!

[Nachos23]

[Nachos23]

Updated Pictures!















They're getting closer. A couple more coats of resin, wet sanding and they'll be ready for clear coat!!!!

[Nachos23]

Time for an update.... Parts are ready for wet sanding.... The intake has already been sanded to 220 wet; next 400 and 800 and then clear coat...... Finally 100, 1500 and 2000 wet, buff and polish and they're ready to go!!





















After I finish this post, I'm picking up a new expansion tank and EGR/Oil separator assembly and associated hoses, heading over to my mechanic buddies garage and replacing those items. Expansion tank has small pin hole leaks (4 tiny pinholes spraying water) and have loi leaking from separator valve. Not bad, considering the car had 260,000km and those a re factory original parts being swapped out!! Going to be busy tonight I guess......

[Nachos23]

The parts have been finished and shipped today!! Here are the finished parts pictures:

























On to the next project!!!

[Grizzy17]

Where did you find the 1x1 weave cloth?

[Nachos23]

1x1 is also known as Plain weave and every supplier that carries the 2x2 will also carry 1x1. I'd check eBay for a local supplier. I'm buying enough quantity per order that I can order direct from manufacturers now, so unless you're ready to commit to 30yrds of it per order, my supplier won't help you as that's their minimum order quantity.