Warped Vents

[doccars]

Stock Louvers

For all it is worth, I recall speaking to one of the Ford GT engineers on this issue. He told me that the later production cars had a more "robust" louver design to help cope with the warping issue. I was also told that supposedly the replacement parts were all of the newer design. From the posts I would be curious to know if the later production GT's are also having this problem.

 

[S592R]

I am open to hear what Fubar and AZGT has been working on. Would prefer CF vents.

I saw a program where they do a type of injection mold carbon fiber but I am unsure of its resistance to heat.

Basically you have two schools of thought here. something easy (plastic, molded etc) or something handmade (probably aluminum ... expensive, bonded to car).

My thought has been to take a duplicate piece made out of aluminum, probably powder coat or jet coat it. Then bond it using an epoxy similar to what we bonded tang fittings into carbon fiber racing sailboats. The loads on those are HUGE and I have never seen a failure. It is a bit of an art to make it look clean as it would need to be on the GT.

As mine have yet to warp I really have not been too much in a hurry to get this project done and have not kicked Shane to move it along. He has sent me a few small pieces to assure me of the quality of the finished product. Being that it is going on a six figure car I wanted to know that before he wasted his time doing the program work and scheduling time on the machine(s).

Personally, if we are looking at something as a group it would probably be best for several of us to sit down, discuss and agree on a part design before anyone bites the bullet on making X number of parts. The parts that Shane are working on is using scrap material, on his spare time and his labor for this little endeavor is free. So in short the R&D here is nothing. I honestly can say I have no idea what this would cost in production or if he is willing to do more than a few pieces. The need is so fractional in an already so small market this is going to have to be a forum project if we want a fix. IMHO.

That is where my little project sits and what my observations are on the subject.

 

[B O N Y]

First I appreciate the energy of Larry and Fubar and am anxious to see what they develop.

I have a serious cf jones, finished another project car that came out well. Although traditionalists cringe when they see it. Now on to the FGT.

I would love to know if the vents could be made out of cf.

I would seem only logical and prudent to ask Stillen, Genandi who are both EXCELLENT forum sponsors to weigh in. After all they are a proven reliable source for top quality products.

What would also be valuable is to learn from Ford how many sets of vents have been replaced through their warranty program.

I am running Stainless WorkS headers and have not heat or cooling issues.

That's my 2 cents!

 

[Derry]

In reply to later production being more robust, I did not find that to be the case. Last October I replaced them on my '06 after a couple of track days. They are since warped again. Just everday semi aggressive cruising:biggrin

 

[AZGT]

Just a quick update.

Supposedly by the end of the week I will have information from a second company about making the cast, original looking aluminum replacements.

Just letting everyone know that the ball has not been dropped.

I am expecting them to be in the target price range.

Stay tuned.

 

[Fubar]

Thank you very much, for the update. Keep us in the loop! :thumbsup

 

[paul b]

How about a scoop of some kind. This could be used as just a cover-up or possibly functional as a cowl induction if the aerodynamics are right.

 

[AtomicGT]

Seems to me, the only vents I have seen warped are the ones that have had Acufab rear exhausts placed. I may be wrong, but I have not seen warping on the stock GT exhausts.

 

[fjpikul]

No, I know Silverbullet's warped before he changed exhaust.


My personal theory is that only warped owners have warped vents. That question was not an option on the panel.

 

[MAD IN NC]

On my third set of side vents right now...... Had them replaced last week by FoMoCo....

 

[Pete S.]

Seems to me, the only vents I have seen warped are the ones that have had Acufab rear exhausts placed. I may be wrong, but I have not seen warping on the stock GT exhausts.

See if this link works to view the set on mine. 17,000 miles, no exhaust mods. The pictures are not good enough to show that some of the warped areas along the seams are starting to crack. Still, I think only we here on the forum notice and even with the wavy vents the cars are spectacular.

http://home.comcast.net/~petraathome/warped01.htm


Pete S.

 

[AZGT]

I know there has been a lot of conversation that maybe the replacement exhaust causes the issue.

I really don't think it does. When I took off my side vents and look where the exhaust is, it really is fairly far away. Yes, the OEM mufflers supposedly had some heat shield, but the warp even occurs on the part of the vents that is over and in front of the air box - exhaust is not even close (probably 2 feet away).

Just for the heck of it, next time we take a run somewhere, I'll take the infrared thermometer and we can do a check of stock versus x-pipe temperatures on the clam and other areas and see if there really is a difference.

One thing I do wonder, and this was just an after thought that just ran through. A lot of us did the license plate spacer. I did the infrared on before and after on it, and didn't seem to see much other than the license plate got a hellova lot hotter. Maybe that changes the airflow and more air escapes higher on the rear - and closer to the vents? Just speculation.

I think the vents are ABS. There are different compounds apparently with ABS that change properties, but the regular stuff (according to internet) has a "maximum" temperature of 176 degrees, and a melting point of 221 degrees. For an engine running 200, makes you wonder, but maybe they did something other than straight ABS. I mentioned before in a post that I looked at higher temperature softening plastics for the vents, but screw plastic. We are going aluminum - we'll probably have new issues, but at least the old issues (melt, UV aging, etc) will be gone (geez, kinda like changing wives :biggrin.)

 

[bob_the_ninja]

for what its worth, i would say the best way to make new vents that look standard for a realistic price would be aluminium castings and then a bit of machining, then paint em up however you like.

 

[AtomicGT]

Haven't seen any warping on the stock exhausts. Only on the modified ones. But then the manufacturers will tell you something else, like it is Ford's Fault or something like that. :cheers

 

[B O N Y]

Doc, my vents have no droop.. all is good in that department. Ran the Accufab and now the Stainless Steel Works headers... Do have some issues with droop, but that is another medical issue we can chat about in PS.

 

[fjpikul]

Bony, have you tried Enzyte? Free trial on TV.

 

[AZGT]

Haven't seen any warping on the stock exhausts. Only on the modified ones. But then the manufacturers will tell you something else, like it is Ford's Fault or something like that. :cheers

It gets both. Problem is that a lot of owners have gone to a modified exhaust, so there is a bias in the outcome.

In the "questionaire" link, I noted that it appears more regional (read as outside temperature) that may be related.

Doesn't matter - I plan to have the cast aluminum version available fairly soon. That will solve the problem without knowing why it occurred.

 

[bob_the_ninja]

are you in the process of getting aluminium castings made? because if you are not and looking for some to be made and enough people want them i may be able to help?
also, whoever does them, they would almost definatly need machining after casting, having them sand cast using the plastic ones as the templaite would reduce set-up costs too.

how much do the ford plastic vents go for because i have a mint set of a very low milage car i could maybe take off!!

 

[AZGT]

Spent some more time on the project yesterday. Think we are making progress. Issues were discussed regarding the type of alumimun and casting (difficult because of the number of fins / runners). Still going forward, as we think we have solved some of the dfficulty issues (see below).

At this point it looks like some preliminary models will be forthcoming, so we will see if they will cast.

Idea still is a set of all four vents, and powder coated black.

More to come, just wanted to let eveyone know that I am still working on the project, and so far is still going forward.

Just got a little delayed - one of the other manufacturers stroked me for 5 weeks before saying they couldn't do it :thumbsdow (Aso had another say not possible, buy they told me in a week - now working with someone that says they think it can be done.).

 

[OCPETE]

Appreciated effort that will payoff to the engineering guru(s) as well as warped FGT owners..anxious for results like the rest of us :thumbsup
Thanks!!