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As mentioned previously, the lip needs to be mounted and scanned as its urethane and its natural shape isn't the same as its mounted shape, but it was pretty close.
New lip scan, this time attached to bumper. I'm going to print up a fit test that matches the inner surface of the lip and bumper to verify. Then adapt the design to the new scan.
I printed a quick test piece to verify fit between the scan and my bumper. hi_im_sean is also printing one to get some idea of how much variation there is between lip installs.
The fit is perfect. I can feel it pop into place and it wants to stay put. The red lines I drew on the part show the edges where I am looking at gaps/fit. There is actually more space to work with on this scan than before, which means more/better flow.
This one is going to be 2.5". 3" is probably possible as well.
Eventually I will scan the R package lip mounted to the bumper to see what is possible. The R package has a smaller opening and more stuff in the way- it might not be possible and it might require cutting some lip plastic (stuff you can't see from outside of the car).
This one is going to be 2.5". 3" is probably possible as well.
Eventually I will scan the R package lip mounted to the bumper to see what is possible. The R package has a smaller opening and more stuff in the way- it might not be possible and it might require cutting some lip plastic (stuff you can't see from outside of the car).
Yes, I was thinking about that, there is that weird half clamshell piece on the inside that might need to go. If the GV lip inlets flow enuogh for a 3" hose I'm sure the R-pkg lip should flow enough to justify a 2.5" hose, I think they're fairly close in size. I'd be willing to let you use my car for R-lip scanning purposes some weekend, Durham's not far...
So the template part fits my lip perfectly and Seans lip imperfectly. We both played with lip mounting position but it seems like there is some variation between the lips (multiple molds?). Add in how much variation there will be in user install and I don't think the lip can be designed to fit everyone with a cosmetically perfect fit. I think the best solution is a small bead of black silicone that seals any gaps on the leading edge. This is going to to be cosmetic, even without the silicone the part is secure. I am printing a PLA test duct right now that is close to a final design.
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