Rear wing - air duct - material type?

[Spenny_b]

Evening guys,

As part of my engine rebuild project, I need to accommodate a new TK intercooler. Rather than simply remove the plastic ducting panel that sits inside the rear wing (which then "buffers" up to the stock 964 Turbo intercooler), I want to rework mine to channel as much air through the intercooler as possible.



What I'm aiming to do, is very similar to what the factory did as stock, but kind of in reverse....i.e., where the stock IC has the shrouding riveted to the IC itself, presenting a flat deck that the wing butts up against, I want to mount this shroud onto the panel in the wing, which will then butt up against the TK intercooler. Clearly I can't (won't!) rivet a shroud onto the TK I/C.

So....in theory relatively straightforward, albeit it's likely to involve many sacrificed cereal packets.

I can order sheets of plastic material easily enough from the guys I've used before ....delrin, acetyl, nylon, etc....I then plan to make it as neat as possible by plastic welding the structure to the panel. Once assembled as a frame, it'll be only supporting its own weight plus the rubber trim to seal the duct.

Clearly I need to order the correct sheeting and filler rod for the plastic welding kit I hope to borrow. It's not stamped into the panel like current plastic parts have to be (recycling legislation).

Does anyone know what material this panel is please?

Thanks in advance

Spencer.

[911nut]

I would think it is HDPE, which is popular with manufacturers due to it's physical properties, manufacturabiity and cost.

[Spenny_b]

Thanks Paul, good man.

Having had a note from our favourite AZ based tuner , I think there's some investigatory work to be done before necessarily going to town and doing what I was going to do, once the engine is installed and run-up. (Thanks Chris!)

As-and-when I know what I'm making - if I need to at all, the stockist I use does indeed carry black HDPE...about £12 for a 1m sq x 2mm sheet.

Cheers
S