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Intake Refinishing Alternative to Powdercoat

 
Old 01-26-2012, 07:57 PM
  #16  
Fogey1
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Originally Posted by olmann View Post
... When reassembling the intake I wanted to level off the surface area of the intake where the intake gasket goes for mounting to the engine. I had to aggressively sand it down to get it off. Even then the primer didn't want to come off easily. Its adhesion is excellent and you can see from the pic where I worked to get it off.

Attachment 602127 ...

Excellent work. Beautiful results.

How did you do the sanding? The first thing that comes to my mind is sandpaper glued on a piece of glass. The second is a long board sander as used in bodywork.
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Old 01-26-2012, 10:05 PM
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Lots of work with a beautiful end result.
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Old 01-26-2012, 10:07 PM
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Originally Posted by Rob Edwards View Post
Outstanding!

When the chemist was 'familiar' with the Mg/Al alloy, did he specify a particular type or composition? Just curious.
He seemed to believe that it was AZ91D.
Attached Images
File Type: pdf
az91d2[1].pdf (442.7 KB, 403 views)
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Old 01-26-2012, 10:08 PM
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Originally Posted by 77tony View Post
Saw these at 3rd Coast this past Nov and they did look great. Nice job Brian. 77Tony
Thanks Tony
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Old 01-26-2012, 10:14 PM
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Originally Posted by NoVector View Post
Outstanding--just bookmarked this page for my top end refresh. After it's stripped, is it possible to lightly sand and fill some of the pits to get a really smooth surface? If a filler can be used, what kind would I use that wouldn't mess up the rest of the process?? Again, great job! / Bruce
If you are wanting an ultra smooth surface I would go through the process and then prime it with an ultra high fill urethane primer instead of the sealer. Once dry fill all the small holes/imperfections with a polyester glazing putty and then sand smooth. The drawback is you will need to sand everything else also so that the paint will stick to the primer. If you are willing to take the extra time it will look perfect!
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Old 01-26-2012, 10:15 PM
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Originally Posted by jbrob007 View Post
See if I can post a pic or two... Paint works if you do the prep. And, I did a TON of prep. Wish I had known about this etching material a month ago! Oh well, maybe next time
That looks top notch to me!
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Old 01-26-2012, 10:19 PM
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Originally Posted by JWise View Post
Anyone who's had a chance to talk to Brian will come away impressed - he's very knowledgeable, thorough, and detail oriented. I had the pleasure of meeting him and seeing his car in person at 3rd Coast. His car was incredible and the intake looks better than factory.

About two years ago, I painted my intake and cam covers with Duplicolor Engine Enamel on top of their self-etching primer. It's held up well, although there are a few places where it has started to bubble, most notably in the cam cover lettering. Note: I did not throroughly strip mine, rather I removed everything that was loose then feathered the edges in with primer and sanding. As such, you could say my prep work was subpar.

I'm not a big fan of powdercoating and will bookmark this thread for use next time. I suspect Brian's method will hold up at least as good as the factory's did, and possibly better given modern materials and our own attention to detail. Thanks for the writeup!
Thanks for nice comments Jarrod. I imagine you could talk me into helping you refinish yours one of these days without too much effort since we are fairly close to each other.
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Old 01-26-2012, 10:20 PM
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Outstanding! Thanks for the write up.
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Old 01-26-2012, 10:21 PM
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Originally Posted by Fogey1 View Post
Excellent work. Beautiful results.

How did you do the sanding? The first thing that comes to my mind is sandpaper glued on a piece of glass. The second is a long board sander as used in bodywork.
I used the flat face of a DA (Dual Action) sander. The key is to keep it flat.
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Old 01-27-2012, 09:46 AM
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Beautiful!
Mods - this should be cross posted in the 928 DIY section. A great alternative to PC.

Question to Op - if you were doing it again, would you mask off the mating/gasket surfaces first?
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Old 01-27-2012, 10:24 AM
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I've bought rolls of 3M stickyback tape in 2-3" varieties. I get 220 grit and stick it down to a granite slab (or piece of glass or any flat surface). with a 32v intake you can lay out strips along the runner lengths and block the whole assembly as one piece. Tha makes sure the whole intake is flat across the board, from side to side and front to back.
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Old 01-27-2012, 11:24 AM
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One thing - either you had the most perfect castings I have ever seen or something in your process eliminated the pock marks and craters I almost always see in the cam covers. Dave Roberts has used and recommended Lab Metal as a filler for these casting flaws. http://www.alvinproducts.com/Products/Products.asp?id=1

How did you get yours so smooth and crater free?
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Old 01-27-2012, 11:44 AM
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I looked at that too, but on the originals I only noticed one small indication of erosion near the 'c' on one of the tappet covers...maybe both an excellent baseline to work from ..
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Old 01-27-2012, 03:22 PM
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VERY NICE!
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Old 01-27-2012, 05:57 PM
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Gorgeous. I plan to do this when I tear into my engine compartment for timing belt etc.. I won't be staying with the stock color though, gonna go with something metallic, and colorful. Liven up the 86 engine bay a bit. Can you give an estimate of total cost (blasting, etcher, sealer, paint, clearcoat)?
Thanks,
Dennis
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