Novak Conversions Jeep Wrangler TJ radiator

What did you do to / in your garage / shop today?

More work in the indoor mancave this weekend, though I have little but destruction (or maybe deconstruction) to show for it.

Decided I wanted to have an indoor spray booth for shooting small parts. The need/desire was born from wanting a small setup to do fine cerakote work on handgun parts, but I figure it may well have other uses in the future. I picked up a suitable airbrush and, as it turns out, the 2 gallon air compressor I replaced when I shot my hardtop recently will work perfectly for indoor use with an airbrush, and it's quiet, too.

I considered buying a plastic portable booth from a place like Amz, but I wasn't feeling it for the money. While buying something would be faster, my hope is to make something potentially a bit better, for less money and using some materials I've already got on hand.

Design criteria:
  • must be somewhat portable/packable
  • incorporate inexpensive, switchable LED lighting for good all around visibility and finish verification
  • incorporate particulate and activated carbon filtration
  • must feature exhaust to exterior via window opening
  • utilize controls, fan motor and impeller from an air purifier as the basis for the extraction fan
  • utilize numerous pieces of 12" x 72" 5mm luan ply coupled with 3D printed parts for booth, blower housing, etc.
The bits I'm starting with, the aforementioned destruction/deconstruction....

View attachment 665959

Suffice it to say this will never function as an air purifier again, no matter what happens from this point forward. Currently working the booth design in CAD, more to follow...unless I get electrocuted or something catches fire in the interim... 🤪

Progress. Magic'd up a suitable housing design in CAD, sliced it and printed in ABS-GF.

cad.jpg

blower1.jpg

Chucked up a sanding drum in the drill press and cleaned off the fin remnants and unified the size. Controls mounted in new faceplate, the white part of the print was supposed to glow with backlighting on the control board, but it seems the BL white ABS has a bit higher solids content so it barely illuminates. Oh well, it was just a last minute trick thing I threw in the design.

blower2.jpg

Proceeded to bond the housing parts using ABS glue and acetone, fishing the power wires before doing so. Once dry, set the fan motor, bonded in the captive nuts for the mounting collar, installed the power jack and fitted the collar to check clearances.

blower3.jpg

Not too bad for a few hours work. Appears to be fully functional and moves air.

blower4.jpg

Next, finalized the basic booth design and dimensions. Currently working on developing this into 3D parts for laser cutting.

booth_sketch.jpg
 
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Progress. Magic'd up a suitable housing design in CAD, sliced it and printed in ABS-GF.

View attachment 668524

View attachment 668525

Chucked up a sanding drum in the drill press and cleaned off the fin remnants and unified the size. Controls mounted in new faceplate, the white part of the print was supposed to glow with backlighting on the control board, but it seem the BL white ABS has a bit higher solids content so it barely illuminates. Oh well, it as just a last minute trick thing I threw in the design.

View attachment 668526

Proceeded to bond the housing parts using ABS glue and acetone, fishing the power wires before doing so. Once dry, set the fan motor, bonded in the captive nuts for the mounting collar, installed the power jack and fitted the collar to check clearances.

View attachment 668527

Not too bad for a few hours work. Appears to be fully functional and moves air.

View attachment 668528

Next, finalized the basic booth design and dimensions. Currently working on developing this into 3D parts for laser cutting.

View attachment 668529

You only made 1/2 of a turbo????? Just think how much air it could make with the other half.... 🤣 🤣 🤣
 
You only made 1/2 of a turbo????? Just think how much air it could make with the other half.... 🤣 🤣 🤣

Funny you say that, I was going to write it up as something like "This thing blows! Dumbass makes plastic turbo for Jeep"... :ROFLMAO:

My volute design does involve a fair bit of guesstimation, if I'm honest. :geek:
 
Progress. Magic'd up a suitable housing design in CAD, sliced it and printed in ABS-GF.

View attachment 668524

View attachment 668525

Chucked up a sanding drum in the drill press and cleaned off the fin remnants and unified the size. Controls mounted in new faceplate, the white part of the print was supposed to glow with backlighting on the control board, but it seems the BL white ABS has a bit higher solids content so it barely illuminates. Oh well, it was just a last minute trick thing I threw in the design.

View attachment 668526

Proceeded to bond the housing parts using ABS glue and acetone, fishing the power wires before doing so. Once dry, set the fan motor, bonded in the captive nuts for the mounting collar, installed the power jack and fitted the collar to check clearances.

View attachment 668527

Not too bad for a few hours work. Appears to be fully functional and moves air.

View attachment 668528

Next, finalized the basic booth design and dimensions. Currently working on developing this into 3D parts for laser cutting.

View attachment 668529
That’s really cool, Chili. That’s some crazy design skill.

Meanwhile, in my shop I’m thrilled that I was able to design a jar to store axle seals…

IMG_9323.jpeg
 
That’s really cool, Chili. That’s some crazy design skill.

Meanwhile, in my shop I’m thrilled that I was able to design a jar to store axle seals…

View attachment 668541

Everyone in this thread is light years ahead of me.........

Anything I did would probably look like a dog turd.........
 
That’s really cool, Chili. That’s some crazy design skill.

Meanwhile, in my shop I’m thrilled that I was able to design a jar to store axle seals…

View attachment 668541

Don't sell yourself short, good geometric construction of things like screw threads are very important skills....and you've got to start somewhere. The fact that you're trying and doing is the important thing. (y)
 
Everyone in this thread is light years ahead of me.........

Not everyone, maybe not anyone, really. To be fair, I've been a designer and CAD jockey for a number of decades now, I should be somewhat good at it....that or I've been an ace bullshitter for the last 35 years and somehow managed to remain employed, but I digress... ;)

Anything I did would probably look like a dog turd

Probably not true, surely you've got some mechanical aptitude (you do own a Jeep) and an eye for things that look good (you purchased a TJ). Everything starts with simple shapes, even the most complex things can be broken down. That fan housing literally started as two stacked cylinders with different radii, doesn't get much simpler than that.
 
That’s really cool, Chili. That’s some crazy design skill.

Meanwhile, in my shop I’m thrilled that I was able to design a jar to store axle seals…

View attachment 668541

Y’all get fancy. I just wash out old peanut butter jars and medicine bottles. 🤣
 
Worked on the road bike a bit last night. Tuned up the drivetrain, cleaned the cogs, & lubed the chain, etc.
Almost ready for another new set of tires…
Not too bad for being 15 years old!
View attachment 669246


CAD aluminum frame with some spinergy…I raced in college and a while after. love it.
 
Novak Conversions Jeep Wrangler TJ radiator