New Carbon Air-box Lids Finished!

[@lefroy1]

Watching this build has been a real exercise in delayed-gratification.. not long now. 😂

[@DanDulac]

I hear you! It’s hard to believe I’m coming up on exactly 3-years since starting this project. Doesn’t seem possible. 👍

[@thebyronmorrow]

So true! I spent about 6 months of sporadic evenings building my Lotus from a roller on up and sometimes wish I would have taken the time to be as OCD as The Dulac is 😅

[@tm06jre97]

The amount of work and dedication in your project it’s insane, thank you for sharing with us. One of the best on KZbin and my favorite.

[@datboi8140]

Easily my favorite series on YT! Keep it up🙏🏻👍🏻

[@williamlanphar630]

I love the tedious attention to detail you employe. I completely agree with the approach of replacing elements that are not optimum with entirely new parts. I anxiously await each episode !

[@stangetz7838]

Dan Dulac for President! And I'm 100% positive! The best build ever! Thank you Dan!

[@jackleonard2088]

At work now but can’t wait to watch this later today. I just love this channel Dan.

[@dukie1616]

The new shape is quite organic and they came out superb as well. Great work Dan👏

[@HemiDartGT]

Nice job Dan, I did the exact same thing on the intake for my Viper. After 2 years, it is still holding up well. A little advice, if you are going to use a hose clamp, reinforce it on the inside with sheetmetal, other when it gets warm, the plastic will squash..

[@bhmsupra]

Excellent work Dan. Good luck with the cockpit area. That will be an exciting phase for sure.

[@anomamos9095]

That centre lock is a bit on the agricultural side. By the looks of it the intention is to put a pad lock on it to lock the lid. Replacing it with a lock from a door or trunk that you can hide the release in the cabin would be a vast improvement.

[@DanDulac]

Agree! I’ve never been a fan of the factory center lock on these cars. I’ll have to noodle on a potential alternative. It’s really not intended to be a structural latch and wondering if I can do without it altogether…

[@anomamos9095]

@@DanDulac . I suggest The latch from either a rear hatch if you want strong or a motorcycle seat if you want small and just a lock. But it definitely looks like a means of locking the lid only.

[@JoelKSLC]

I really enjoy seeing this build come together. Great work Dan!

[@andreworth8493]

Nice! Love this build!

[@SupercarSeany]

Maybe been mentioned, but this thing is deserving of some custom valve covers - even if you just have the oem ones painted, etc.

[@iankirwan8156]

Hello again Dan. Really enjoyed seeing it go from cad model to finished item, installed and looking great. Using one opening as a handle is a useful feature, but I'd fear it might detract from the overall appearance to have some with, some without mesh. The reinforcement you've planned for the underside is also good thinking. As always, can't wait to see the next installment

[@protouringsierra4530]

Great work man. Looks killer! Proper planning prevents piss poor performance.

[@MapleRidgeHomestead]

Dan, you never cease to amaze me with your skills, I can't wait to see this done!

[@DanDulac]

Thanks Paul...and likewise, your projects are just as impressive!

[@dave5833]

Another Great Video Dan I use Y2K clear all the time saves the clean up. Can’t wait to see what you do with the rear clam. I’d keep it clear to show of the Power Plant.

[@manicdogfood]

Amazing work Dan. Profesh a.f. This is shaping up to be a ripper!

[@peterbonnez]

Wonderful work. I'm really enjoying your build.

[@denis9450]

Hi Dan outstanding work if you are thinking of covering the rocker box's I would do it in clear perspex so you can still see then all the best from Liverpool

[@jackleonard2088]

Dan this was worth the wait. Looks so professional! Keep up the great work.

[@TheJekyll400]

Lookin great, Dan! Keep up the good work!

[@sean123456789]

You should do a hexigon grill with a hand opening built it

[@brianbohannon8044]

The OCD in me badly wants to straighten or affix the wire looms next to the plenums lol. Great job on the improved air boxes! You have way more patience than me

[@johngreen8693]

Love the work Dan, and the detail! I just used a tent with dust sheets when I painted in the garage and it worked well - after I also covered the floor... The gold heat shields are great, I would get a better mask though when sanding fibres... Thought about measuring the temp in those tight areas? "..under the bonnet" - British?? A bit of foam/ felt on the clam where it is close to the air box incase of movement/ scratching? Apologies for the queries/ comments! That rear clam is stunning.

[@franciscoovejero9773]

nice work men! congrats! they seems stingrays! beatifull!

[@ndpesicgroup]

Looks incredible !!! Great work !!!

[@staffa007]

Awesome!!! Cheers from Italy!!!

[@GasoliniASMR]

Great work. I really enjoyed that. Thanks for the carbon fibre demo.

[@Pantera-if3fy]

JB weld my favorite shop assistant!

[@DanDulac]

Best stuff ever! I love using the JB Kwik as it sets in just 5 minutes-helps keep the project rolling. 👍

[@carguyuk7525]

Amazing what you have achieved. You must live in your garage. How many hours has your build been? I hope the driving experience is as great as the building. When I built my kitcar the build was by far the best bit.

[@DanDulac]

I have no idea on how many hours I’ve put into it…but it will be exactly 3 years tomorrow since receiving the kit. Time flies when you’re having fun! 😁

[@raymundjusay4632]

🙌🏽 Great Design & Work 🔥🔥🔥💯🔥🔥🔥, I wish you are my neighbor I want to learn from you.

[@steeltree-fabricatingandcu3796]

Elegoo Neptune 4 max high speed printer 14x14x15 print volume You also need a 3 inch orbital DA harbor freight sells one cheap I have two a Cornwell and snapon I love them both

[@DanDulac]

Yep! I’ve since bought one. Amazing print volume for such a good price. 👍

[@macman6107]

That all looks great Dan.

[@Superbatman93]

A roof scoop intake would’ve been super cool

[@DanDulac]

Agreed! Perhaps a project down the road. 😁

[@brian.pautsch]

Love the exposed engine. Incredible fabrication work with those intakes. The carbon fiber is gorgeous. Are you keeping the exhaust pipes that long?

[@DanDulac]

Thanks for your kind words! Now that I've done carbon skinning like this for a second time, practice certainly makes perfect...Good question on my exhaust--short answer: no. Long answer: I've assembled the parts to build a valved exhaust tail section to replace those pipes. Not sure when I'll get to it but it's on my list!

[@brian.pautsch]

@@DanDulac wow...we're all dying to see that thing on the road.

[@randomwerks3763]

I'm loving all the custom touches! I've been watching your videos for a while and love your approach to finding solutions! I'm also thinking about getting a 3-D printer-- I believe it would be a big help in my build. What model do you have, and can it print from an Autocad based program? I work in Autocad and I'm not really looking to learn a new program. Thanks

[@DanDulac]

Hi there! I have a Prusa i3MK3S--it's a few years old now but works great and has never given me troubles. But it does have a small(er) build plate which can be a limiting factor based on the size of prints you want to create. Prusa is coming out with a new large format printer, called the XL, which I've pre-ordered. But I've also heard amazing reviews of the new Bambu Lab X1 printer in the same price range...For 3D CAD design, I use AutoDesk Fusion360 but any CAD program that can export models in STL or 3MF format will work. You then import this file into any of the available 3D printer slicer applications to generate a gcode file that the printer can consume. Hope this helps point you in the right direction!

[@randomwerks3763]

@@DanDulac Thanks Dan!

[@waynebrown3587]

Been watching since day one. I only have 1 question for you DD, how do you pick which of your magnificent fleet to drive. :)

[@DanDulac]

In the summer when the weather is nice, it sure doesn’t suck having to make a choice. 🙏🤟

[@craigjarvis9677]

👍👍

[@awl98]

Maybe use the intake pipes for air ducts internally

[@jjmcoupebmw6557]

Maybe just me, but I'd be worried about little bits of epoxy/glue from the joints breaking free over time and being ingested. I'd be tempted to skin the inside with something as well to avoid this from potentially happening. I might be nitpicking.

[@DanDulac]

You make an excellent point! Coating the inside of the lids with a thin layer of high temp epoxy would be easy to do. Cheap insurance for a potentially very expensive mistake!

[@riccardopreda2148]

Dan, like always, awesome job. Really impressed by your technical knowledge is so many fields! Should I know the name of your 3d printer? I'm thinking to buy one, but it's like a jungle... Any advice? Thx! Richard

[@DanDulac]

Hi Riccardo! I have a Prusa i3MK3S--it's a few years old now but works great and has never given me troubles. Prusa also has a huge user community so there's always answers readily available as you climb the learning curve. But it does have a small(er) build plate which can be a limiting factor based on the size of prints you want to create. Prusa is coming out with a new large format printer, called the XL, which I've pre-ordered. But I've also heard amazing reviews of the new Bambu Lab X1 printer in the same price range. Hope this helps!

[@stevetrepanier4351]

Dan, I like this construction method and am thinking about a similar project. What filament did you use? One of my concerns is the 3d printed material sustaining heat,vibration and in my case, some PCV vapors. Did you look into this much with your filament choice?

[@DanDulac]

Hi Steve! I meant to include the filament I used in the video so good question. For automotive parts, I almost exclusively use carbon fiber infused nylon. It withstands high temperatures, is strong yet flexible and is chemical resistant. Some call it “black aluminum” given these properties. Also, since Nylon is hydroscopic, it actually strengthens when exposed to the elements. But this also means it can be tricky to print if it’s not thoroughly dry; but once you get it right, there are so many uses for this stuff. I highly recommend it. Hope this helps!

[@stevetrepanier4351]

@Dan Dulac thanks! That helps send me down that path. I'll do some more reading on it. I have a 2J mk2 as well and it would be nice to make a better intake and some brake ducts for it with this method. Did you find any tricks for defining how much space you had to work with in the engine bay? I may 3d print a sort of tiered platform that I can bolt to a fixed datum in the car and use play-doh to find the hood contact points at specific measurements away from the datum.....but am always looking for new methods.

[@DanDulac]

@@stevetrepanier4351 The method you describe for test fitting into tight spaces is a good--I use the same method. I also 3D print mock-up models using cheap PLA filament as I get closer to a final model...it helps me tweak the final model before printing with expensive carbon fiber nylon.

[@l33tLX]

Is that open cell foam to ‘seal’ the lids? Might want to reconsider that one.

[@DanDulac]

When I ordered the stuff from McMaster Carr, I intended to get closed foam. I’ll have to double check!

[@l33tLX]

@@DanDulac good man. Don’t want a whistle

[@DanDulac]

I confirmed it’s closed cell, oil resistant neoprene foam. Hopefully it holds up; if not, it’s easy to replace.

[@Shadowband72]

I like me good quality chocolate bar once in awhile , but singing an entire song about it 🤔

[@harveylee65]

Nice job on the carbon fiber I am just not a fan of the carbon fiber look

[@tazanteflight8670]

If you want subscribers, you should upload a video every week. You should create a reddit account, and post links to your videos in all the car, and 3d printing subs. You should include "3d printing" in the title or on the thumbnail.

[@DanDulac]

Great idea with the 3D printing angle...since I do so much of it, I'm sure the 3D printing community might enjoy it.

[@garycmewtowe3065]

...maybe use tube rather than rod....should be more rigid.....maybe.......all is good.....

[@huddleberryfin]

Looks really mean! Here’s a video which may help your stiffening issue. 17min mark ish… kzbin.info/www/bejne/fX65YXikpZamopY

[@DanDulac]

Great share! Thank you!

[@marcopolo6590]

In every video we want to hear her growl Dan !!!!!! 🥇 ❤ From Italy ❤

[@DanDulac]

Good to know! 😁