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View Full Version : POD BOX 3rd Gens NEARLY FINISHED!!!



EZ Boy
01-06-2005, 08:02 PM
Started a new thread to gather up the people who are DEFINATELY in the market for the POD Box.

Need numbers to try and get a break on the moulding price and bulk discount on sealant materials, wing - nuts etc.

Expecting the price to be $160.00 plus freight costs.

If you have questions on the product CLICK HERE

The lid design is a variation of the Poll Winning design - basically the Mitsubishi Logo was dropped for legal reasons.

The final unit will be supplied with almost any size CAI you want to join to it. Current mould options on CAI pipe are: 50mm, 60mm, 75mm, 80mm, 90mm and 100mm.


So I need from Interested Peoples:

"Say yes I'm keen. Price is good. I run 90mm (whatever diameter you run) pipe from my cai or intend to run. I'm likely to order ....(estimate date or timeframe)."

The List so far:

EZ Boy
Mrs EZ Boy
broke
Badmagna
DaJaJa
VRADA
Hunter
vrx578
THE VATT
cogs
Icarian
BRICK
Addict
TJ VRX
Anon

MAYBE:

Zaphod
97_verada

Zaphod
01-06-2005, 08:18 PM
I want to say definitely yes to this, but can't, so put me down as a definite maybe. Won't be for a couple of months though. No idea about pipe sizes, as I don't already have a CAI. Price seems a little high but I could probably wear it.

broke
01-06-2005, 08:24 PM
yeah definately, let me know when it gets the time and i will more than likely grab me one of those.

Badmagna
01-06-2005, 08:37 PM
yep, sign me up, price is good. I don't run any CAI piping (how much do you think piping would be worth?)at the moment, just have a 99 TH Magna sports with K&N pod, so what ever fits and gives best performance I would be happy with.
Would like something this month in next week or two, as I need to have the car blueslipped and it might not pass with an exposed pod :(

I have the money now, consider this a firm order, when can you deliver?
P.s are you the guy who does the throttle bodies too?

DaJaJa
01-06-2005, 09:05 PM
looks well done!

this is just with BOX only in the price and not including the pod???

yes I'm keen. Price is good. I run 90mm

VRADA
01-06-2005, 10:50 PM
I have ordered a Ram Pod and its on its way now...
I would definatley be up for one of your boxes, good on you eh for taking the initative.
If 90mm is the biggest u can fit down then im definatley up for the 90mm piping hole.

Design looks good, pm if u want money details etc... dont expect u to do it all out of your own pocket.

laters :D

Hunter
02-06-2005, 05:48 AM
Def put me down for one! Im in the same boat as some of the others with the pipe sizes, im not really sure what I will end up running....just an idea but perhaps if u were able to source some pipe as well you might be able to sell them as complete kits. I know I would certainly be happy to pay a premium price for the reduction in hassles. Anyway just an idea. Just out of interest wha size pipe have most ppl been running, was it hard to get thru, where did you get it??? Brilliant work tho, should be a winner!

vrx578
02-06-2005, 06:48 AM
YES!! I am in for sure! Bargin price considering the materials and effort needed in making one.
With the pipe size, no idea. I take it a 90mm pipe would fit down in between battery housing and radiator to front bumper. If so, then 90mm it is.

broke
02-06-2005, 07:51 AM
will any circular pod filter work? cause i can pick those Blitz pods pretty cheap around here. Or does everything think stick with K&N??

THE VATT
02-06-2005, 08:18 AM
Plz be adding THE VATT to your list...

I can make payment before hand if you like too!!!!
Damn thats a good price

Oh yeah prob 90mm

EZ Boy
02-06-2005, 08:32 PM
PEOPLE WITHOUT CAI'S:

Duck into a plumbing place and ask for a couple of fittings in various large sizes. Run out to the carpark and check clearances past the battery box, radiator lines etc.

I had to 'shoe-horn' the 90mm into my AWD and actually had to cut the battery box and patch it with convex 100mm pvc glues in place.

On the other hand, my TF 5spd manual looks like it will handle 90mm very comfortably.

So please check to save some heartache - I can't *unmold* the cai join up. ;)


POD filters size: We mostly use the K&N for their reputation and compatibility with the MAS sensor intake. Other filters have been trial with varying reports of sucess and failure.



MONEY: I wont ask anyone for money or a deposit even until I am happy with the unit. If I'm not happy, no one has been messed around.

Thanks for the support and kind words - keep them coming lol

97_verada
02-06-2005, 09:02 PM
PEOPLE WITHOUT CAI'S:

Duck into a plumbing place and ask for a couple of fittings in various large sizes. Run out to the carpark and check clearances past the battery box, radiator lines etc.

I had to 'shoe-horn' the 90mm into my AWD and actually had to cut the battery box and patch it with convex 100mm pvc glues in place.

On the other hand, my TF 5spd manual looks like it will handle 90mm very comfortably.

So please check to save some heartache - I can't *unmold* the cai join up. ;)


POD filters size: We mostly use the K&N for their reputation and compatibility with the MAS sensor intake. Other filters have been trial with varying reports of sucess and failure.



MONEY: I wont ask anyone for money or a deposit even until I am happy with the unit. If I'm not happy, no one has been messed around.

Thanks for the support and kind words - keep them coming lol

your a champ ian, good to see you getting off your bum and making some stuff for the magna, ill prob get one eventually but no timeframe as yet. Got to get an exhaust first, hey that reminds me did you get my last PM? Just put my stereo in and a bit behind in my rates at the moment so maybe when that catches up and exhasut is installed ill come to newy and see ya.
cheers mate
jaz

cogs
02-06-2005, 09:26 PM
Ill take one for sure, planning to run 90mm CAI in my TF.
Let me know when u want money etc, hope it works out

Icarian
03-06-2005, 03:40 AM
Q: Would I like one?
A: Yes

Q: What CAI Piping do you run?
A: I Don't have CAI yet as I was literatly about to start it when you started you post about the box. I am planning on running 90mm as that seems 2 be a popular choice.

Q: When am I likely to order?
A: When can you get it to me?

Hunter
03-06-2005, 05:45 AM
Thanks for check out the pipe sizes etc EZ....much appreciated :) You can def pencil me in for a box with a 90mm input. Cheers

Badmagna
03-06-2005, 06:29 AM
Looks like everyone else is kinda keen on the 90mm, I am happy to go with that ez boy

TJ VRX
03-06-2005, 06:39 AM
Definately one for me, got any pics of the box yet?

BRICK
03-06-2005, 06:07 PM
yeah mate sign me up, and i want what ever the biggest cai i can fit in weather that be 100 or 90 i dunno will talk to u about it laters

EZ Boy
03-06-2005, 06:44 PM
No pics yet - my camera is on it's way back from RICOH with a new lense sub assembly or something to the tune of $201.00!

My man at the Plastic Co. goes on holidays all next week so I'll be taking this opportunity to fine tune the design and not rush an error thru that will set me back. That would really peev me off, esp since I'm paying for it!

Definately hoping to have a unit churned out week of June 12th, unless I can coherse his offsider to run one off for me :badgrin:

EZ Boy
03-06-2005, 06:59 PM
Extra juicy info:

I am designing the unit on my TF 3L, which has a shorter engine height hence less movement in the inlet pipe joining the TB and MAS. This way there is definately enough play to fit the 3.5L which I will confirm in my AWD.

Mould is identical to the shown illustration, pattern yet to be done along with final sanding.

Zaphod
03-06-2005, 08:56 PM
No pics yet - my camera is on it's way back from RICOH with a new lense sub assembly or something to the tune of $201.00!
I could probably drop by over the weekend and snap some pics if you like..

green_TF
05-06-2005, 06:55 PM
Hey guys, first post every so don't hack it to bits too quickly. Just wondering, if i get this pod box, the pod and some flexible 90mm piping is this all i need? do i need any special adaptors to fit the pod up to the MAS/MAF/whatever it is called? i take it the pod box will just bolt on to where panel box came off of.

One other question (may seem a little silly), where do you guys run your piping to? i've seen some people run it down to the fog light, but that looks a bit dodgy (at least to the police). i was thinking maybe just have it pointing straight down? would appreciate any opinion, especially any TF owners. also saw one guy that just hacked holes into the fog light cover thing, thought that was unique :)

Thanks

eek
05-06-2005, 07:08 PM
hey, would u think a 5" round pod would fit in this box?

The Photographer
05-06-2005, 07:35 PM
im possibly in for the second production run.

i would like to hear from other users first before i fork out that money plus a pod, considering i just layed down 140 for a K&N panel filter

pomejo
06-06-2005, 08:21 AM
i cant say ye untill you sent me the info i need

EZ Boy
09-06-2005, 09:39 PM
i cant say ye untill you sent me the info i need

Understood, and I'd luv to give you final measurements. The brackets and sealing lips need to be upgraded to accomodate the available space etc. The costs are starting to creep up and that's bugging me :doubt:

Bloody hope to get ONE box made this week coming!! F*ck I need some closure on this project!

green_TF
09-06-2005, 10:17 PM
Just one or two quick questions. is the lid going to be held on by clips (like the stock one) or will it just push on and stay in place. Where is it going to be split in half, not overly important but i am just interested. will it be on the axis of the holes (for mas/maf and our own cai), that would be my guess to make it easy to mold. sum pics would be good. Keep up the good work mate.

jay04
10-06-2005, 06:16 AM
Question: Can you supple everything thats needed for the CAI as a package deal? I only have the pod and nothing else. Also how much do you think shipping is to the US?

EZ Boy
10-06-2005, 08:49 PM
Just one or two quick questions. is the lid going to be held on by clips (like the stock one) or will it just push on and stay in place. Where is it going to be split in half, not overly important but i am just interested. will it be on the axis of the holes (for mas/maf and our own cai), that would be my guess to make it easy to mold. sum pics would be good. Keep up the good work mate.

The lid will be held together at 4 points from my design phase 1. The inlet pipe is split and will be held together by the CAI rubber joiner being hose clamped around it. It is made of 3mm ABS so has plenty of surface area and strength. The other 3 points are wing nut bolts that fasten the lid on and complete the seal around the neoprene(?) insert that will be fitted.

My camera is still in the shop :angrybastard: but there's nothing useful to show people at present. The images posted are more useful to look at then the mould at present.

Jay04: I can send them anywhere on Earth I suppose. $ - no idea, will get one for you when the final weight and dimensions come through. Because of the various combinations of engines and transmissions and vehicle clearances (at least 8?) it'll be up to you to organise a cai. The cost of shipping to you components of a CAI that are no doubt readily available to you is also pointless.

green_TF
11-06-2005, 10:12 AM
The inlet pipe is split and will be held together by the CAI rubber joiner being hose clamped around it. It is made of 3mm ABS so has plenty of surface area and strength.

So our cai pipe will go on the outside of the inlet of the box, and then be clamped around it? If this is what is happening the inlet will only be 84mm instead of 90mm (90 - 3X2). that means almost a 13% decrease in area (easier calculation to do than you'd think). Don't get me wrong, i'm not saying what you're makeing is bad, i'm just trying to better understand it, and if possible offer some helpful input (not overly likely). Btw I'm guessing it'll be injection moulded which means you can't really thin down the inlet (uniform wall thickness and all)?

Zaphod
11-06-2005, 10:17 AM
My camera is still in the shop :angrybastard: but there's nothing useful to show people at present. The images posted are more useful to look at then the mould at present.
As I mentioned a while back, I often drive close by your place, happy to stop in some time and take some pics if you want to. Also more than happy to give you some time under my car when you're ready to start looking at doing 3.5L FWD extractors.

EZ Boy
12-06-2005, 07:10 PM
So our cai pipe will go on the outside of the inlet of the box, and then be clamped around it? If this is what is happening the inlet will only be 84mm instead of 90mm (90 - 3X2). that means almost a 13% decrease in area (easier calculation to do than you'd think). Don't get me wrong, i'm not saying what you're makeing is bad, i'm just trying to better understand it, and if possible offer some helpful input (not overly likely). Btw I'm guessing it'll be injection moulded which means you can't really thin down the inlet (uniform wall thickness and all)?

Not really. See illustration. My pvc cai mate's up very nicely to my custom pod box using a flexible rubber joiner that maintains the highest internal diameter.

Actually the unit will be vac moulded for ease of $ and time and convenience etc. Mind you I think there will be bigger restrictions inside the MAS to TB corrogated elbow, the 90deg bends in most people's cai's leading upto the pod etc.

The primary function of the box is and remains to reduce the Illegality of our POD filters and too eliminate hot air induction

1st unit will be churned out this week!!!! :pray:

EZ Boy
12-06-2005, 07:17 PM
As I mentioned a while back, I often drive close by your place, happy to stop in some time and take some pics if you want to. Also more than happy to give you some time under my car when you're ready to start looking at doing 3.5L FWD extractors.

I will probably need to take you up on both offers - my camera is still "in transit" or some bullsh!t :cry:

Zaphod
12-06-2005, 07:24 PM
I will probably need to take you up on both offers - my camera is still "in transit" or some bullsh!t :cry:
No worries. Might have 5 minutes to drop in tomorrow and snap some pics if you like.

green_TF
12-06-2005, 07:24 PM
ok, that makes complete sense, was just thinking about in the wrong way, i though you meant the cai pipe would go around the out side of the inlet to the box, thus the outside of the inlet would be 90mm and the inside of the inlet only 84mm. I realise the main function of the box is to gain legallity of using the pod, and cold air of course. Can't wait to see it mate. make sure you have a working camera at your disposal when you get it done. All i can say about you and your initiative is :bowdown:

EZ Boy
12-06-2005, 07:43 PM
No worries. Might have 5 minutes to drop in tomorrow and snap some pics if you like.

I haven't got the box made yet. The mould has been modified to streamline airflow further. I'm getting very sneaky in my old age.

Will get in touch when it's done, or I'll just lob at your front door one night :cool:

Zaphod
12-06-2005, 07:45 PM
I haven't got the box made yet. The mould has been modified to streamline airflow further. I'm getting very sneaky in my old age.

Will get in touch when it's done, or I'll just lob at your front door one night :cool:
Okies, np. :)

green_TF
12-06-2005, 07:53 PM
I haven't got the box made yet. The mould has been modified to streamline airflow further. I'm getting very sneaky in my old age.

How can you say something like that and then just disappear into the night :confused: I'm sure all will be revealed when it's finished:think:

EZ Boy
14-06-2005, 09:59 AM
THE MOULD IS FINISHED!!

Dropping it off tomorrow morning - early. Will see if I need to change anything and will leave it with The Man to do his thing and give me a call when it's done.

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!

THE VATT
14-06-2005, 10:04 AM
THE MOULD IS FINISHED!!

Dropping it off tomorrow morning - early. Will see if I need to change anything and will leave it with The Man to do his thing and give me a call when it's done.

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!

I'm likin the sound of this!!!!!

green_TF
14-06-2005, 05:05 PM
Any chance for a pic of the mold?

EZ Boy
14-06-2005, 08:08 PM
Any chance for a pic of the mold?

Sorry, top secret - even bigger than the PS41 :bowrofl:

green_TF
14-06-2005, 08:11 PM
Sorry, top secret - even bigger than the PS41 :bowrofl:

It'll prob look better too

97_verada
14-06-2005, 08:17 PM
It'll prob look better too

for sure judging off EZ_Boys current one they will look like a smick stealth install should.

Zaphod
14-06-2005, 08:19 PM
Damn, I'd better hurry up and do something about my insurance so I can fit one of these puppies when they're ready..

JoeNess
16-06-2005, 08:24 PM
IM a maybe, price is good would run 75mm pipe.

The Photographer
16-06-2005, 09:17 PM
is the intake size debate exactly the same as the exaust size debate
size versus velocity ??/

and what is the ideal size
ENGINEERS COME ON

or is bigger better
i was dreaming up a great idea for a intake today at work then i realised the radiator was in the way, haha maybe i should just do my work.

green_TF
17-06-2005, 07:15 AM
is the intake size debate exactly the same as the exaust size debate
size versus velocity ??/

I thought the mass flow rate would be most important (yes air does have weight). so if you have a larger area the air does not need to be travelling as fast to have the same amount reaching the pod. also if you want to get really complicated, when air flows through a pipe, the air at the edge of the pipe travels slower (due to a boundary layer being formed :shock: ). this disrupts the flow near the edge, therefore the free flowing are actually has a reduced area that it can flow at the required speed. btw i am not an engineer, i'm an engineering student so this is probably all wrong :confused:

green_TF
17-06-2005, 04:42 PM
1st unit will be churned out this week!!!! :pray:

It's the end of the week. How we looking? were there any unforseen moulding issues?

EZ Boy
17-06-2005, 08:37 PM
It's the end of the week. How we looking? were there any unforseen moulding issues?

A few problems. My mould wont survive many (if any :doubt:) runs and needs some reinforcement and redesign of one minor area. This will unfortunately limit the variety of inlet diameters available for the POD Box.

What I'm going to do is get two moulds done in 90mm (if the mould will last) and get these epoxied. These Epoxies will become the moulds. One will be 90mm and the other 75mm. The rubber joiners have a good degree of tolerance to join different diameter pipe to the airbox.

Need more sleep :coffee:

WogsRus
17-06-2005, 08:37 PM
I thought the mass flow rate would be most important (yes air does have weight). so if you have a larger area the air does not need to be travelling as fast to have the same amount reaching the pod. also if you want to get really complicated, when air flows through a pipe, the air at the edge of the pipe travels slower (due to a boundary layer being formed :shock: ). this disrupts the flow near the edge, therefore the free flowing are actually has a reduced area that it can flow at the required speed. btw i am not an engineer, i'm an engineering student so this is probably all wrong :confused:

Well I’m and engineer and I can back up what you have said. The larger pipe will allow more movement of UNDISTURBED air. The boundary layer on a smaller pipe decreases the actual UNDISTURBED air to the plenum. The smaller pipe will have higher velocity which in turn increases the friction at the boundary layer causing lower flow. As a Side effect of the larger pipe there will be a higher pressure gradient available for the engine. SO for example if someone actually made an CAI in such a way that it was fully sealed so that the entering air could only go down the intake and not leak anywhere you would be forcing air in at a higher pressure into the plenum, p1v1=p2v2 principle.

HOWEVER saying all that, each intake has to be correctly sized to the plenum design. You can have a good CAI and a bad Plenum and you will make no difference. AND then you open up a whole can of worms. For those who are familiar with NA motors, the size on the inlet runner and its length dictates the amount of horsepower developed and where it will be developed.

In a NA car as air is drawn into the engine it creates a low pressure zone behind the valve, as the valve close a high pressure wave is formed and starts to travel back up the runner. This creates a pressure gradient for when the next time the valve is opened, this cycle continues. The length of the runner will dictate at what rpm the timing of the outgoing and incoming waves match the engine characteristics to develop optimum power. WELL that's the simple version.

For the person who is creating the intakes if you have a chace avoid any 90 degree bends. A 90 degree bend has a pressure loss coefficient relative to velocity of roughly .43 depending on size. A 3.5 lt engine will suck in 350 litters of air per second at 6000 rpm, which is a lot of air so if we are running a 90mm pipe, the velocity of the entering air will be 58m/s and that is high, causing turbulence problems. To get the best out of the inlet make sure that any sizing changes are smooth and gradual. There is a lot that makes a good intake great.

If you like send me and email of some basic design parameters and layouts and I can do a design check to see where we can improve air flow.

m_jankowiak@hotmail.com

Ok that's enough for now. I think you get the picture.
LOL

EZ Boy
21-06-2005, 07:09 PM
The first vac forming session exposed a weak area of my mold. :redface:

Attempts to correct this have resulted in the mold becoming terminal and a new mold has been started and will be done by the weekend.

Armed with this knowledge it should be a cakewalk from here on in.

Thanks for the patience and continued PM's chanting support. :thumbsup:

green_TF
02-07-2005, 06:23 PM
Hey EZ, how's this project going?

pomejo
03-07-2005, 12:19 PM
i was thinking this box may fit in a evo as the evo box is bigger then a stock lancer so i want one for my evo vlll
so can you make me one please ez boy
and can they be painted

HyperTF
03-07-2005, 02:05 PM
I have been holding off making mine ;) to see how you go.

whitemagna
03-07-2005, 02:24 PM
im very interested just as i said to you befor i just want to have a look at it first to see what size pipping i need but yes put me down as interested

thanks

Geoff

Ralliart Boy
03-07-2005, 05:43 PM
Im in EZ BOY as discussed. Can i have my piping in Stainless Steel ??

EZ Boy
04-07-2005, 06:36 AM
Hey EZ, how's this project going?
Going to try a different tack today. The mold is ok, but I need a backup plan and there is smash repairer in the same complex as our Muffler Shop.

Can anyone spell: "PLASTIC WELDING"? If this is a goer might be able to cut the price unless they want stupid money to do the work. :doubt:

Sorry this is dragging out, I'm low on time and $. I think most of us can relate to this. My TB and POD BOX projects are things I try to get to in my spare time each week.


Stainless is do-able. Custom scoop ram-air intake too hey?

Painted maybe - can use different coloured plastic if that's helpful, will find out.

The vac molded item was modified to accept 100mm standard, with additional molds planned for 90 and 75mm only. Stepper fittings would need to be used for other sizes. The Welded item could probably fit ANY size inlet upto the 100mm mark. Will investigate tube fabrication or availability.

green_TF
04-07-2005, 11:02 AM
It's a bit strange when you here the words plastic and welding in the same sentence hey EZ, i know it confused me. What sort of welding are you planing on? Will it just be hot plate welding?


Sorry this is dragging out, I'm low on time and $. I think most of us can relate to this. My TB and POD BOX projects are things I try to get to in my spare time each week.

I think i speak for everyone when i say this, we all apreciate the time any effort ($$$) that you put in. Take your time so that you can be proud of the finished product. :bowdown:

HyperTF
04-07-2005, 05:53 PM
...Can anyone spell: "PLASTIC WELDING"? If this is a goer might be able to cut the price unless they want stupid money to do the work. :doubt:

I use to weld plastics and it would be an option worth considering, but the welding process is not as simple as it sounds... bad weld, poor life. Material choice is important too. What were you thinking of welding? the whole thing?

I was concerned that this was going to cost you. I hope you get a break soon.

EZ Boy
05-07-2005, 07:49 AM
Plastic welding is like oxy welding to a dgree. A core of filler is fed into a hot air stream and melted into the join, fusing with the softened parent material. I have seen some VERY strong plastic welded items including a dash console. I was quite impressed.

I do believe my mold will work, I just thought I'd investigate all bases.

You're absolutley right. I want to do this properly. If I'm not happy with the item, I can't expect anyone else to just 'cope' with it after forking out hard earned bling.

EZ Boy
13-07-2005, 06:15 PM
*** UPDATE ***

The mold IS FINISHED and is at the Plastic dude's factory to be done this week.


(this is a brief pause while you cheer loudly)


He's flat out with work atm and said to drop back next Tuesday to see how it went. He was very impressed with the mold even with the high sides. Said it wont be a drama at all. Cool

'bout time. And I learnt to MIG weld yesterday.

What a funky week. :D

el3ment
13-07-2005, 06:24 PM
Sweet. Can't wait to see some pics of the product. :)

SUBishi
13-07-2005, 06:51 PM
*** UPDATE ***

The mold IS FINISHED and is at the Plastic dude's factory to be done this week.


(this is a brief pause while you cheer loudly)


He's flat out with work atm and said to drop back next Tuesday to see how it went. He was very impressed with the mold even with the high sides. Said it wont be a drama at all. Cool

'bout time. And I learnt to MIG weld yesterday.

What a funky week. :D
good stuff here is the cheer

(picture at the footy field on grand final day)

aaarrrrrarararrarararararar, yayayayayayyyaaaaaaa
wooooootttttt
good stuff can't wait to have a perv

Zaphod
13-07-2005, 07:09 PM
/me cheers loudly :D:badgrin:

Skippy
13-07-2005, 07:24 PM
:bowrofl: EZBOY :bowrofl: :cool:

Icarian
14-07-2005, 02:20 AM
Sounds like your having lots of fun and an interesting time with this project :)

EZ, just take your time and make sure that the end result is what you wanted, I know you will have an excelent result :)

Thanks for all the time and dollars you put into things ! :)

*Cheers loudly*

HyperTF
27-07-2005, 08:30 PM
*cough* how did it go EZBoy?

EZ Boy
27-07-2005, 08:37 PM
OK it moulded very well. We now know that we should've used 4.5mm not 3mm ABS. As the sheet was draw over the mould it thinned out of course :doubt: It's just too thin for me to be comfy with.

Seems I need to adjust some areas of the mould before it's next vac press.

Once I've got the mould done I need to generate an epoxy mould to become THE mould for all future vacuum mouldings to be done from.

Here's the problem: That's gunna cost me $300-$400!! Just for the epoxy. :cry:

Just going to have to start saving or sell more throttle bodies....

HyperTF
27-07-2005, 08:47 PM
I used to do all this stuff (interests me heaps...plus I am interested in potentially buying the end product!!)... is the vacuum former ceramic heated? can you control where the heat is concentrated?... it will make a hell of a difference (i.e. cooler in the middle and hotter on the edges)... but yeah... that gauge seems a little thin... good luck... hope you aren't going bust over it!

Thanks for the update!... good luck!

choonga
27-07-2005, 09:14 PM
OK it moulded very well. We now know that we should've used 4.5mm not 3mm ABS. As the sheet was draw over the mould it thinned out of course :doubt: It's just too thin for me to be comfy with.

Seems I need to adjust some areas of the mould before it's next vac press.

Once I've got the mould done I need to generate an epoxy mould to become THE mould for all future vacuum mouldings to be done from.

Here's the problem: That's gunna cost me $300-$400!! Just for the epoxy. :cry:

Just going to have to start saving or sell more throttle bodies....
make one outta wood?

EZ Boy
27-07-2005, 09:27 PM
make one outta wood?
Done that. They wont survive multiple mouldings so an aluminium epoxy one is made which is very strong and will last for a very long time. That's the big cost problem.

heathyoung
28-07-2005, 09:47 AM
I have had some success with using car body filler for doing fibreglass moulds - aluminium loaded epoxy is very exxy...

Cheers
Heath Young

HyperTF
22-08-2005, 06:56 PM
Any progress mate?

EZ Boy
22-08-2005, 07:06 PM
I think I'm going to have to concede defeat with the vacuum molded approach. It all sounded good on paper :cry:

I am looking into plastic welding and carbon fibre as alternate construction methods. I will update this area as information and developments progress.

A big thanks to everyone for keeping on my back to help keep the fires burning in me to get a result. Unfortunately this one's too tough with the approach I took so I'll regroup and reorganise my assault. Thanks again :)

The Photographer
22-08-2005, 07:06 PM
you seem to be putting alot of effort into these mate. i might have to grab one off ya once there finished along side a Flowed TB.

Ill keep watching, it seems to be an interesting process.

HyperTF
22-08-2005, 07:09 PM
Oh well, good on you for trying anyway... I will go ahead and get my butt into gear and make a box... problem is there are very few places I have found that will sell thick gauge plastic sheeting... bunnings only seems to go up to 3-4.5mm (from memory)... need something a bit more sturdier... plasticised PVC sheeting would be great if only I could find it.

EZ Boy
23-08-2005, 05:09 PM
New Development: I found a nice and CHEAP plastic welding set today that I'm going to save up for. I have plenty of contacts in the local plastic industry now so I will be able to source what I need to construct the airboxes and other custom work. This should be fun lol

cogs
23-08-2005, 10:23 PM
Sounds good, cant wait till these are finished, hanging out to get one. Good luck in it all

EZ Boy
24-08-2005, 08:19 PM
Ok, blew my entire R&D budget today. Bought a plastic welding kit :shock:

All I have to do now is figure out how to use it.... Just kidding. It's like TIG welding. Hoping to build the boxes, inlets, scoops etc using plastic welding of ABS.

Will keep everyone updated.

Badmagna
23-09-2005, 11:16 AM
Giday TZABOY, any updates on this pod box?

HyperTF
23-09-2005, 12:53 PM
Giday TZABOY, any updates on this pod box?
I think you mean EZ Boy ;)

Badmagna
23-09-2005, 01:07 PM
Oops I did, sorry EZ Boy :redface:

s|r_b00st
25-09-2005, 06:04 AM
im possibly in for the second production run.

i would like to hear from other users first before i fork out that money plus a pod, considering i just layed down 140 for a K&N panel filter


im in exactly the same boat.. DAMMIT!

Fergo
25-09-2005, 06:24 PM
yep same me, id love one of these!!!
my pod atm is sucking hot dirty air through it.

_stonesour_
25-09-2005, 06:27 PM
far as i know he is on a 3 week holiday from AMC ... moving house i think he said ...

EZ Boy
29-09-2005, 08:56 PM
I'M BACK......

1st Pod Box for 3rd Gen is 99% completed as we speak(?). This will be fitted with a custom inlet scoop to a RALLIART running in the Newcastle leg of MM05 this Sunday.

I am also showcasing another mod on the same car that I have released.

If you can't get there (afternoon) there will be heaps of pics taken and opinions formed no doubt.

Remember this is the VERY FIRST one of these I've done so my process will be refined as time goes.

Good to be back.

Now, about cheap broadband.......

Ralliart Boy
29-09-2005, 09:09 PM
VRX ??

It's a Ralliart !!!


I look forward to seeing it on my car and appreciate your efforts in making it happen this Sunday.

EZ Boy
29-09-2005, 09:35 PM
VRX ??

It's a Ralliart !!!


I look forward to seeing it on my car and appreciate your efforts in making it happen this Sunday.
:redface: I was reading a post on VRX springs while waiting for this page to load.

Bet you're wondering what the *secret* mod is!


We might have to watch the Grandfinal in your CAR!

Ralliart Boy
01-10-2005, 03:49 PM
Phew, glad we got that sorted !!!

Yes, very interested to what this secret mod of ytours is, i guess time will tell.

I have 5 seats available for the grand final in my car, one screen each at $500 per ticket.

Zaphod
01-10-2005, 05:06 PM
1st Pod Box for 3rd Gen is 99% completed as we speak(?). This will be fitted with a custom inlet scoop to a RALLIART running in the Newcastle leg of MM05 this Sunday.

I am also showcasing another mod on the same car that I have released.
I sure hope that's a Newcastle car, eh EZ? :eh:

EZ Boy
01-10-2005, 09:18 PM
I hope people appreciate how long this has taken to look like this:

My wife has given me my ABSOLUTE LAST WARNING about how much time I spend in the shed.

So, subcontractors needed. Apply by PM.

EZ Boy
01-10-2005, 09:20 PM
$500 per ticket.
:shock:
Wanna come with a lap dance and a smorgasboard. Not from you thou. :bowrofl:

The Photographer
02-10-2005, 06:21 AM
Here ya go, now u can actually see it.
http://i7.photobucket.com/albums/y285/Skando1/RIMG0060smallerlighter.jpg

EZ Boy
02-10-2005, 07:47 PM
Here ya go, now u can actually see it.
http://i7.photobucket.com/albums/y285/Skando1/RIMG0060smallerlighter.jpg
How'd you do that!?!

Skippy
02-10-2005, 08:06 PM
How'd you do that!?!we are not happy because they were in in newcastle today and didn't come to the cruise for mm05 not good guys every anger about it, it shows you don't care about amc

Skippy
02-10-2005, 08:11 PM
I'M BACK......

1st Pod Box for 3rd Gen is 99% completed as we speak(?). This will be fitted with a custom inlet scoop to a RALLIART running in the Newcastle leg of MM05 this Sunday.

.......
to bad ezboy it every came to town like you said it was not good dude. By the way the newcastle group is not happy about it dude you have lost my bussines over or of it because you don't wanty to be apart or NMC which is your local town dude ,it sad dude ,SAY 3825 962 dude

The Photographer
02-10-2005, 08:17 PM
How'd you do that!?!

magic

EZ Boy
02-10-2005, 08:32 PM
we are not happy because they were in in newcastle today and didn't come to the cruise for mm05 not good guys every anger about it, it shows you don't care about amcEveryone can relax and take a chill pill. We were still fitting the TB and goodies at 3:45pm today. My wife got called in to work (surgical team at Hospital) so I was the babysitter (this ALWAYS BLOODY HAPPENS WHEN I'VE MADE PLANS!! :rant:).

As to what the 3 cars that came to my place did after, I have no idea or control over. I do know that they had full intentions of getting into Newcastle to meet everyone once the TB and Pod box etc was installed. Unfortunately this dragged on due largely to the complexity of locating the intake in the Ralliart front bumper and squeezing the Pod Box past some sort of gismo attached to the TCL functioning. (see pics)

I am disappointed that I couldn't get to see everyone. It's been a VERY long time between 'drinks' and now that the chaos of moving house and rushing TB's and CAI's thru for people over the last 2wks is over I can try and salvage my marriage and get to some local events.


it shows you don't care about amcThat's a bit heavy. I spent from 6:30pm to 11pm every night last week designing and configuring these Pod Boxes and cai as well as countless phonecalls to locate the distributer of the TPR Ducting that I am using as well as recommending to people who are doing their own cai work. (TPR ducting is oil resistant, and most chemical resistant. Can withstand temperatures within the range of -20 to 125'C. It's spiral bound with wire so it's strong and very flexible.)

For this estimated 20+ hours spent last week I collected a HUGE $160. :nuts: Sounds like love and not reward to me.

Oh, and I've been without internet and land phone for damn near 3weeks while Telstra and Downer play hot potato with who's responsible for getting my f*cking phone connected.

EZ Boy
02-10-2005, 08:43 PM
Why do I have to justify to ANYONE on AMC or NMC what the f*ck I do with my time and life?

Pretty sure I don't.:angry:

Skippy
02-10-2005, 08:44 PM
Everyone can relax and take a chill pill. We were still fitting the TB and goodies at 3:45pm today. My wife got called in to work (surgical team at Hospital) so I was the babysitter (this ALWAYS BLOODY HAPPENS WHEN I'VE MADE PLANS!! :rant:).

As to what the 3 cars that came to my place did after, I have no idea or control over. I do know that they had full intentions of getting into Newcastle to meet everyone once the TB and Pod box etc was installed. Unfortunately this dragged on due largely to the complexity of locating the intake in the Ralliart front bumper and squeezing the Pod Box past some sort of gismo attached to the TCL functioning. (see pics)

I am disappointed that I couldn't get to see everyone. It's been a VERY long time between 'drinks' and now that the chaos of moving house and rushing TB's and CAI's thru for people over the last 2wks is over I can try and salvage my marriage and get to some local events.
sorry to here that bro but a phone call would have been nice and by the way the raliiarts who took off it would have been like to onfo some one


That's a bit heavy. I spent from 6:30pm to 11pm every night last week designing and configuring these Pod Boxes and cai as well as countless phonecalls to locate the distributer of the TPR Ducting that I am using as well as recommend to people doing their own cai work.

For this estimated 20+ hours spent last week I collected a HUGE $160. :nuts: Sounds like love and not reward to me.

Oh, and I've been without internet and land phone for damn near 3weeks while Telstra and Downer play hot potato with who's responsible for getting my f*cking phone connected.well sorry ezboy but it would have been nice if you had say something but no you don't it and by way it would have been nice if the ralliart had telled someone what they are doing

EZ Boy
02-10-2005, 08:50 PM
well sorry ezboy but it would have been nice if you had say something but no you don't it and by way it would have been nice if the ralliart had telled someone what they are doing
So I should have put done tools, an emailed someone? I don't have current contact details for anyone in NMC, maybe Zaphods # is still somewhere handy. Maybe. It just seemed more important to me that the job was done correctly and quickly so that we could make our way or at least get the show car down to Newy but it wasn't to be and couldn't be helped.

It's pretty hard making a custom intake for a vehicle that I've never seen. :doubt:


Anyway, what do people think of what they're seeing in the pics?

Skippy
02-10-2005, 08:50 PM
Why do I have to justify to ANYONE on AMC or NMC what the f*ck I do with my time and life?

Pretty sure I don't.:angry:
ok mate you have three kids plus a bussniess and keep to you word i do because not can sorry not to people at anytime

The Photographer
02-10-2005, 08:53 PM
im not entirely wise to whats going on here but i think what ez boy is doing for the club is great. i dont think he needs all that ****.

Anyways pics look good mate, once i get my car back i might get u to hook me up, with a flowed TB and pod box and whatever else youve made before march 06

HyperTF
02-10-2005, 08:54 PM
OK settle it down thanks, there is obviously more to this story but I think enough has been said already. Time to move on.

Skippy
02-10-2005, 08:58 PM
lol why

HyperTF
02-10-2005, 09:02 PM
lol why
Because I will start to get more serious that's why.

Skippy
02-10-2005, 09:15 PM
it a free country so i say what i want

MODern ENGINEuity
02-10-2005, 09:20 PM
And you say it with bad spelling and grammar, leave it alone.

GRDPuck
02-10-2005, 09:41 PM
...Anyway, what do people think of what they're seeing in the pics?
Looks good EZBoy!!! What's it perform / sound like ? Give us some descriptions, feelings, thoughts, verdicts, dreams, (sigh - awaiting one for the 2nd Gens...) Costs?

eek
02-10-2005, 10:08 PM
so how's this one different to what was in ur awd? lol seems pretty similar eh?


btw, skippy, calm down, he couldn't make it....its over now. Family was more important than going to a car club event...go get some sleep.

_stonesour_
02-10-2005, 11:43 PM
so sell the concept to me EZY BOY .... tell me why i should get this and replace it with my RPW style intake ? :P

Disciple
03-10-2005, 05:45 AM
Where's the pipe in the front go to or get air from? Under the car somewhere?

Badmagna
03-10-2005, 07:50 AM
Looks sweeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeet man :D
FANTASIC JOB
When can I get my hands on one of these and go and :nutkick:falcodores? hehe
(just found the nutkick icon, so I had to try it!)

GoTRICE
03-10-2005, 07:58 AM
top work ez-boy; not being ignorant i can tell how much work you've put into the club even while your moving house and you've got kids etc :thumbsup:

Badmagna
03-10-2005, 08:05 AM
EZ Boy, one quick question, in the pics of the ralliart with your new pod box fitted you seem to have removed the plastic cover which usually sits over and around the battery.

It looks like your Pod Box takes a fair amount of room (as you would expect) but does it force you to remove that plastic cover over the battery?

Ralliart Boy
03-10-2005, 08:28 AM
For a start, it was my car that the work was done on.

EZBoy has done a fantastic job and i thank him for that. Everything has gone well last night while driving the car with no hiccups.

And i think Skippy needs to take a long look at himself and get his facts straight before shooting his mouth.

Who the hell are you to talk like that to EZBoy ?? He does not have to justify himself to you or anyone.

The plan was to get the work done and then come to Newcastle to show it off but due to problems we had, plans changed and i didnt come to Newcastle as my life does not revolve around you and i had other plans that night to which i had to get back for.

And, you say that i didnt tell anybody, your wrong, all the Sydney people knew about it and i even repeated that when i met with them in the morning.

Maybe they dont like you and dont feel they need to answer to you either.

With an attitude like you have, its no wonder.

So have a cry, grab a tissue, build a bridge and get over it.

Jealousy is a curse mate, dont let it get the better of you.

GRDPuck
03-10-2005, 08:41 AM
...So have a cry, grab a tissue, build a bridge and get over it...
Good post 'Ralliart Boy' - maybe now we can all get over the 'EZ Boy - Skippy' FEUD and get back on topic of what's more important...
How does it perform, sound, cost, where does the pipe go, details, etc. :badgrin:

Come on 3rd GENers - get your wallets out and buy some (or at least state your interest - not sure if EZ Boy is ready for orders so I guess I should leave that to him :redface: ) - then EZ Boy may get to earn some $$$ and make up with his family so he can design a 2nd GEN EZ-PodBox lol
.

Flava
03-10-2005, 08:45 AM
As soon as these are available to all, I'd love to ahve one. It's just what I need to push me into a pod.
Fantastic work EZ Boy. I'm impressed and appreciate that you've found time to develop an almost impossible to source accessory for our Magna's.
EDIT: I just need to work out what size pipe i can squeeze between the battery and the extra bits for the auto tranny. Any ideas? Anyone?

TZABOY
03-10-2005, 08:54 AM
i help ezboy install it yesterday and the job is of very good quality. If it had been a bolt in job we would of been at the foreshore mid arvo but no, like most custome jobs it took time and it took longer than expected.

Not everyone's lives revolve around amc, or nmc for that matter. By the looks of people's boots yesterday morning your intention was just to drink drink and drink some more-very un amc i believe.

Skip, in the past you have seemed to be a nice guy, so remind me next time you dont make an event

Icarian
03-10-2005, 09:11 AM
EZ Boy does not have to justify himself to you or anyone, he has slaved his arse off for projects that will greatly benifit AMC and magna owners...

Anyways, looks like top work EZ :clap: :thumbsup: :clap:

I'm keen to see progress in this project, like someone else said, it is just what I needed to give that final push into the world of PODs.

How does it sound?
Performance inhancment?

jay04
03-10-2005, 09:24 AM
EZ Boy does not have to justify himself to you or anyone, he has slaved his arse off for projects that will greatly benifit AMC and magna owners...

Anyways, looks like top work EZ :clap: :thumbsup: :clap:

I'm keen to see progress in this project, like someone else said, it is just what I needed to give that final push into the world of PODs.

How does it sound?
Performance inhancment?

and how much?

biohazard
03-10-2005, 09:47 AM
i help ezboy install it yesterday and the job is of very good quality. If it had been a bolt in job we would of been at the foreshore mid arvo but no, like most custome jobs it took time and it took longer than expected.

Not everyone's lives revolve around amc, or nmc for that matter. By the looks of people's boots yesterday morning your intention was just to drink drink and drink some more-very un amc i believe.

Skip, in the past you have seemed to be a nice guy, so remind me next time you dont make an event

Well the attitude of the ralliart drivers has now come into everyones vision.

Congratulations on alienating yourself from the Newcastle scene. As usual you idiots only think of yourselves. Last time you came up to newcastlse, you acted like 'b' grade idiots, drag racing then getting spooked and running away like a bunch of girls. This time you sod off during an event with no-one knowing where you guys were.

Just disapointed with you're efforts. People were perhaps looking forward to seeing your and the others cars yesterday, but then again; if it aint all about you...

smiddy
03-10-2005, 10:05 AM
:nuts: think bout it man...
1. read wot has been said about it by every1
2. THINK about it!!
3. THINK about what it does for the club
4. GET OVER IT!!!!!

now i know thats a lot to remember and think bout but i hope you can do it.

HyperTF
03-10-2005, 10:14 AM
I have already had to post a please move on message

http://www.aussiemagna.com/forums/showpost.php?p=366201&postcount=105

Now back on topic, or I will have no choice but to take action on it.

Ice_Magik
03-10-2005, 12:40 PM
10 points for yor efforts ezboy !!!!!!!!!!!!!

can we get some more details if possible ?

availability, pricing, how the unit is fitted, where and what it is attached to so it wont move.

also, what the final product will be made from, how it is molded, as this will indicate how well it deflects / absorbs heat, and will give a good idea of general toughness...

_stonesour_
03-10-2005, 02:01 PM
already p[osted this once but i think it got lost in all that mumbo jumbo of the past 2 pages.........

EZY BOY tell us why we should get this as opposed to the RPW style intake ... pro's and cons please:D

BTW love ur work! ever thought of selling ur concept/ moulds to performance companies? i think ur ripping ur self off :P lol

Ralliart Boy
03-10-2005, 08:56 PM
Well the attitude of the ralliart drivers has now come into everyones vision.

Congratulations on alienating yourself from the Newcastle scene. As usual you idiots only think of yourselves. Last time you came up to newcastlse, you acted like 'b' grade idiots, drag racing then getting spooked and running away like a bunch of girls. This time you sod off during an event with no-one knowing where you guys were.

Just disapointed with you're efforts. People were perhaps looking forward to seeing your and the others cars yesterday, but then again; if it aint all about you...


How dare you, what gives you the god damn right to call me what you did, your a tool.

Another clown who shoots off at the keyboard to make himself feel big without knowing all the facts.

Why be jealous for, you might grow up and own (or finance in your case as obviously your uneducated) a Ralliart of your own. If the bank approves it, you may even have enough left to modify it.

And yes, my car is for me and i had all intentions of showing you guys when it was done but it took a lot longer than expected which happens in the car modification game sometimes. Go and grab a tissue off one of your other Newie mates who mouthed off at the keyboard before and help him to build that bridge.

Why is it i have to report my movements to you anyway but if you checked your facts, every person that left from Sydney knew exactly where i was so you were welcome to come and see for yourself but i guess drinking beer and mouthing off at the keyboard is more your style.

Im glad I didnt show you now, you dont deserve to be in the same postcode as me or my car.

HyperTF
03-10-2005, 09:16 PM
My god this is pathetic, people, FFS pull your heads in!!! EZ Boy Feel free to start a new thread. If is see any of what I have through this thread in your new one, i will start cool down bannings.

It's rediculous I just don't have enough boxes of tissues to hand out.

Good on you all for killing this thread. Hope you are happy!

=CLOSED=