AP2 Cooler Ducts are Finished!

I made these for a friend of mine that is planning on running an intercooler on each side of his bumper (Porsche GT2RS style). These take air from the front bumper, just like our brake ducts, and funnel that air into your cooler. These are perfect for putting an oil cooler inside of your fender liner so that you don't block off air from the radiator. They are super lightweight with a 0.15" wall thickness.

It ended up being the biggest piece I have ever made. It is much larger than my machine's capabilities (12"x12"x15") so I ended up printing it in 3 separate pieces. I then "welded" those pieces together using my soldering iron since the melting temp of PLA is around 200C. 

I can't wait to see how these look and function installed!

Here is when we test fitted them on his car. The Stoptech Trophy kit sure in beautiful by the way..

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CFD analysis I conducted at 100MPH, atmospheric pressure at outlet to see how the air would behave. This was an iterative process to get the best possible velocity field.

CFD analysis I conducted at 100MPH, atmospheric pressure at outlet to see how the air would behave. This was an iterative process to get the best possible velocity field.

Finished product

Finished product

Finished product

Finished product