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Thread: Rally Racer needs 2.3L / 2.5L Help Reply to Thread
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Topic Review (Newest First)
11-21-2015 11:28 PM
The Mold

So the mold came off very very clean. Two air voids that needed to be filled and sanded (bondo). Then, final coat of gel-coat and i now have a mold ready to pull 100 carbon or kevlar dashboards

Tomorrow - skim coat of epoxy, let her tack up, lay down first layer of carbon fiber

11-19-2015 11:07 PM
felixthecat Looks great^^^^^^^
11-19-2015 09:00 PM
Mold is set.....

So to recap....

Pulled the dash
taped off all vent holds, button holes, etc
covered in bondo
sanded bondo
painted with GelCoat 2 part polyester
three coats of mold release wax
three coats of PartAll #10 PVA (mold release)
Painted another coat of gelcoat to be "face" of the mold
covered with 3/4 layers of chopped strand
Tommorrow, i pull the mold off the plug (dash) clean her up, and start laying up some carbon :)

11-18-2015 10:47 AM
Carbon Fiber Focus DASH

So I got a bit more nit-picky than i usually do (VW dash was a C-) so i prepped and sanded, and filled, and sanded, and then finally this AM covered in Gel Coat the dash.

Now time to let her set up all day and tomorrow AM give her 5 coats of wax, 2 coats of Part All Mold Release - then paint on another layer of gelcoat (will be face of mold) let that tack - then hand lay down the fiberglass chop strand and resin to make the mold.

BTW - after I get this mold done - anyone who wants a carbon fiber dash and is willing to pay for supplies and shipping or pickup (YORK/KITTERY MAINE) - just lemme know
11-16-2015 11:46 AM
Carbon Fiber Dash Time :)

Ok, so have a bit of time and decided a fun refresh would be to take out my old dash - template it - and then do it and the center tunnel in carbon fiber (also delete the glove box as its just wasted space/weight for us on stage.

Step by Step Carbon Fiber Dash process i used (again, i race cars and sell software - not a pro by any means at fabrication)

Done so far
1. Remove dash
2. masking tape off all voids

3. smear with bondo - making as many sharp angles smooth - avoiding "negative" angles that will not release form mold

4. sand to smooth all bondo coverage - fill in all gaps, dips, blems, etc (in progress now - oh joy ;)
11-15-2015 01:24 AM
sailor Great pics!

Nice to hear how it's been going, big plans for the off season again.
11-15-2015 12:11 AM
Rally Car Update

Hey folks. Only got to do one rally this year - but thankfully it was on a new set of ProFlex Rally Suspension, a new KaaZ Diff, and now its time for a refresh.
  • Adding Quaife Straight Cut Gears aka DogBox
  • Adding Carbon Fiber Dash and Center Tunnel (will post mold building process, and then carbon fiber work)
  • Tearing the motor down again to deck the head, and have an engine shop re polish and port my 2.3l head on the 2.5l block.

09-30-2014 09:29 AM
1turbofocus I now have custom made 2.5 H-Beam rods in stock with custom ARP rod bolts for 399.00 these rods will hold 600hp easy

09-26-2014 02:29 PM
Originally Posted by 408wkash View Post
Talk to Karl at Massive before you take Toms device. Alot of guys have done VERY succesful 2.5 builds with the 2.5 head revving to the moon.
With the 2.5 liter, due to it's high stroke (3.93), the pistons speeds are very high. Revving at 9000rpm the piston linear velocity will be at 30m/s, near Formula 1 engines.

Like Tom said, for a high revving 2.5 you'll need good forged internals and a dry sump, at least.

IMHO, even with forged internals a 2.5 revving this high will not last too much.
The force between piston and cylinder walls (high rod angle x high rpm) will be very high resulting in premature cylinder wear.
09-24-2014 09:38 PM
K Dog If you READ my post you see that I also recommended a dry sump for sustained 9k usage. We have always used a flow bench to test anything requiring it. Certainly anyone can always get a set of custom rods made. But we have them on the shelf. As we've always stated we have the only commercially available 2.5 rods. This way they can be obtained with no guess work, can be shipped immediately and don't have the "custom" set of rods price tag.
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