Airflow Headlights for Naturally Aspirated and Forced Induction Motors

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Airflow Headlights For Naturally Aspirated and Forced Induction Motors

A Baccalaureate thesis submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati

in partial fulfillment of the requirements for the degree of

Bachelor of Science

in Mechanical Engineering Technology

Nicholas Andrew Hardert

April 2014

Thesis Advisor: Professor Ahmed Elgafy, PhD

ACKNOWLEDGEMENTS

I would like to dedicate this project to my wonderful friends and family that have stood by me and supported me during this journey. Also I would like to thank Professor Ahmed Elgafy for supporting me through this project and for all the insightful knowledge he instilled upon me.

TABLE OF CONTENTS

ACKNOWLEDGEMENTS ...... II TABLE OF CONTENTS ...... III LIST OF FIGURES ...... IV LIST OF TABLES ...... IV ABSTRACT ...... V INTRODUCTION ...... 1 METHODS OF INCREASING AIRFLOW ...... 1

HOMEMADE ...... 1 HEADLIGHT FUNNEL ...... 3 PREDATOR HIDDEN HEADLIGHT GRILLE ...... 3 CUSTOMER FEEDBACK, FEATURES, AND OBJECTIVES ...... 4

INTERVIEWS ...... 4 SURVEY ANALYSIS ...... 4 PRODUCT FEATURES AND OBJECTIVES ...... 5 DESIGN ...... 6

CONCEPT DESIGN ...... 6 CURRENT DESIGN ...... 8 CALCULATIONS ...... 8

STARTING PARAMETERS ...... 8 STRESS ANALYSIS ...... 8 THE ASSEMBLY DESIGN DETAILS ...... 9

DISASSEMBLY ...... 9 ASSEMBLY...... 9 DRAWINGS ...... 13 TESTING ...... 13

PROOF OF DESIGN ...... 13 RESULTS ...... 14 CONCLUSION ...... 16 SCHEDULE AND BUDGET ...... 17 WORKS CITED ...... 18 APPENDIX A - RESEARCH ...... 19 APPENDIX B - SURVEY RESULTS ...... 25 APPENDIX C - QUALITY FUNCTION DEPLOYMENT (QFD) ...... 26 APPENDIX D - PRODUCT OBJECTIVES ...... 27 APPENDIX E - SCHEDUELE ...... 28

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APPENDIX F - BUDGET ...... 29 APPENDIX G - DRAWINGS AND PART SPECIFICATIONS ...... 30

LIST OF FIGURES Figure 1- Airflow Model ...... 1 Figure 2 - NMRA Certified Vehicle ...... 1 Figure 3-Fabricated Air-Box...... 2 Figure 4-Fiberglass Headlight...... 2 Figure 5-Functioning Headlight ...... 3 Figure 6- Round Headlight Funnel ...... 3 Figure 7-Rectangular Headlight Funnel...... 3 Figure 8- Predator Hidden Headlight Grille ...... 4 Figure 9 – Dual Headlight Concept ...... 7 Figure 10 – Side Intake Inlet Concept ...... 7 Figure 11 – Front Structural support ...... 7 Figure 12 – Current Design...... 8 Figure 13 – Static Pressure FEA ...... 9 Figure 14 – Disassembled Headlight ...... 9 Figure 15 – 3D Printed Components ...... 10 Figure 16 – Lens ...... 10 Figure 17 – Lens ...... 10 Figure 18 - Saw Blade...... 11 Figure 19 – Magnetic Lens ...... 11 Figure 20 – Reassembly ...... 11 Figure 21 – Projector Housing ...... 12 Figure 22 – Light Assembly Modification...... 12 Figure 23 – Light Bulb Modification ...... 12 Figure 24 – Final Assembly ...... 13 Figure 25 – Removable Lens with Seal ...... 13 Figure 26 - Mass Air Flow Vs RPM ...... 15 Figure 27 - Mass Air Flow Vs MPH ...... 15 Figure 28 - Mass Air Flow Vs RPM ...... 16 Figure 29 - Mass Air Flow Vs MPH ...... 16

LIST OF TABLES Table 1- Customer Survey Results 5 Table 2-Project Milestones 17 Table 3- Project Budget 17

ABSTRACT

The focus of this design project is to design, build and test a functioning headlight capable of allowing air to flow directly into an engine’s air intake system. The concept behind this project was to create a design that could be quickly installed, utilized by the driver from within the vehicle, and obtain the maximum efficiency of the intake system to increase power and torque produced by the engine. For this project the following improvements over the stock design were a 15% increase in the mass air flow at wide open throttle and an increase in throttle response.

The design was fabricated utilizing an existing headlight fixture and 3D printed components. The fabrication was completed over the course of several steps, including disassembly, component fitting, surface finishing, and sealing. The proof of concept design was inserted into a 2003 Ford Mustang for performance testing. The three tests conducted were performance on the street, performance on the track and resistance to the elements on the street. Based on the results of the testing, the design was unsuccessful in 3 of the 4 requirements; the design was waterproof.

Overall, this project was a success even though the product was unable to meet the required increase in horsepower, torque and mass air flow. It is clear that the newly designed Air Flow headlight does in fact increase the amount of air entering the engine at a high rate of speed, while at wide open throttle by 15%.

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INTRODUCTION

The focus of this design project is to design, build and test a functioning headlight capable of allowing air to flow directly into an engine’s air intake system. This eliminates the need for cutting a hole in the front end of a car or removing the headlight to increase airflow into the intake system.

The options are limited for race enthusiasts who want to increase the amount of air going into their intake system. One way to achieve this however is to take advantage of the air flowing across the front of the car as seen in figure 1 (1) below.

Figure 1- Airflow Model

The racing community has taken it upon themselves to fabricate their own methods due to the lack of commercially available products. The following sections will describe some of those methods as well as discuss the commercially available options.

METHODS OF INCREASING AIRFLOW HOMEMADE A common method race enthusiasts prefer is cutting a large hole in the front bumper of their car to allow for direct airflow into the intake system, as shown in figure 2 (4). The issue with this method is that it is only ideal for strictly race vehicles, because the hole allows water to enter the intake system thus entering the motor damaging internal components. To avoid this street cars on the track typically remove the headlight to try to achieve the same effect but with the option to reattach the headlight, sealing the hole.

Figure 2 - NMRA Certified Vehicle

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Race enthusiasts have designed their own headlight fixtures to take advantage of the airflow on the front of the vehicle. Figure 3 (5) is a design of a fabricated air-box that fits in place of the cars headlight capturing air flowing over the edge of the car. The issue with this design is that it not only takes a considerable amount of fabrication to the existing brackets and mounts and it will also allow water to funnel into the intake system.

Figure 3-Fabricated Air-Box

Another option for racers is to use fiberglass to mold OEM headlight shaped inserts that funnel air into the intake system, shown in figure 4 (6). This design also allows zero protection against the elements and debris that could be on the roads or in the air.

Figure 4-Fiberglass Headlight

The last design has been taken a step further by fabricating a fully functioning headlight that allows for air to flow into the intake system. The two designs seen in figure 5 (7) (8) (9), below, are similar to the proposed design in the fact that the racer desired a functioning headlights, as well as, increased airflow. What this design lacks, however, is a water proof system that eliminates exposure to the elements while driving day to day. Also, the light that was removed to allow space for the air to flow through was one of the smaller areas. The idea can be improved by utilizing superior LED and halo style projection lighting along with a well designed housing that allows for maximum volume of air flow.

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Figure 5-Functioning Headlight

HEADLIGHT FUNNEL Two commercially available products that are designed for older vehicles with single circular and rectangular headlights are shown in figures 6 and 7 (10) (11). These commercially available products replace a headlight with a metal cylindrical cone or plastic rectangular funnel allowing an increase of airflow into the intake system. Like the previous designs, these, too, are not waterproof nor do they retain the option to use the headlight. These designs also limit versatility; only fitting into a certain year range and headlight configuration on vehicles.

Figure 6- Round Headlight Funnel

Figure 7-Rectangular Headlight Funnel

PREDATOR HIDDEN HEADLIGHT GRILLE Another option for solving this issue is a ram-air or equivalent air box where the air is being directed through the grill of the car into a cold air intake then directly in through the top of the intake manifold. This is a new design, shown in figure 8 (12), by Chevy utilizes a new grille in conjunction with their optional Falcon Ram Intake System. The grille’s integrated center mounted air duct directs air into the Falcon Ram system, which replaces the factory air box with a cold-air tunnel that routes over the top of the radiator, through a unique low-

3 Airflow Headlights Nick Hardert restriction air filter and directly into the throttle body, increasing both power and response. While this design is slightly different than utilizing the headlight the concept is the same.

Figure 8- Predator Hidden Headlight Grille

CUSTOMER FEEDBACK, FEATURES, AND OBJECTIVES INTERVIEWS “Competitors would be looking for a design that fits their specific vehicle and that flows well with the rest of the car’s design,” says experienced IHRA racer, Brian Engler. He also mentioned that most race vehicles are taken by trailer to the track and are rarely driven at night. So this product would need to be marketed to a specific group of racers such as the Sportsman class. (2)

“Competitors are constantly looking for ways to improve the air flow to their engines to give them an edge. Most racers tend to do this modification themselves do to the lack of products on the market,” says experienced IHRA racer, Jake Prewitt (3)

After speaking with product consumers the important design features for a successful product on the market were understood; see Appendix A for further research. Based on this information, the improvements to current methods and products were determined.

SURVEY ANALYSIS 10 customer surveys were distributed, returned and analyzed to determine the customer needs. The surveys were completed by three NMRA certified racers, one NHRA certified racer, three engineers, two mechanics, and one field specialist to get a wide range of customer feedback (See Appendix B for full survey and customer results). The survey included a wide range of product features arranged in categories of operation/function, safety and cost. The first question on the survey focused on customer importance as they were asked to rate the importance of features on a scale from 1-5 with 5 being the highest importance. The results in Table 1 have been sorted from highest relative weight to least relative weight. The second question on the survey listed these same questions but surveyed the customer for satisfaction. The satisfaction is ranked on a scale from 1-5 with 5 being the most satisfied. Results are shown below in Table 1 under the Current Satisfaction category. Table 1 also shows the Planned Satisfaction for each of the customer feature categories.

By looking at Table 1 you can see that the most important customer feature for this product is for it to be completely waterproof, which is both a safety and reliability issue. By looking at

4 Airflow Headlights Nick Hardert the Planned Satisfaction category, which is the satisfaction of the customer with the Airflow Headlight prototype, there is a 420% improvement over current commercial products. This is due to the fact that all of the methods researched and discussed are not waterproof and only some can be made waterproof with another product. For full QFD analysis refer to Appendix C.

Table 1- Customer Survey Results

Nick Hardert Airflow Headlight 9 = Strong 3 = Moderate

1 = Weak

Customer importance Customer Satisfaction Current Satisfaction Planned ratio Improvement Importance Modified weight Relative % weight Relative Waterproof 4.7 1.2 5 4.2 19.6 0.34 34% Amount of Airflow 5 3.8 4.5 1.2 5.9 0.10 10% Ease of Use 4.7 4 5 1.3 5.9 0.10 10% Appearance 3.8 3 4 1.3 5.1 0.09 9% Durability 4.3 3.9 4.5 1.2 5.0 0.08 8% Reliability 4.1 4.3 5 1.2 4.8 0.08 8% Safety 3.7 4.8 5 1.0 3.9 0.07 7% Ease of Installation 4 3.9 4 1.0 4.1 0.07 7% Veratility 3.6 2.5 3 1.2 4.3 0.07 7% Low Cost 3.5 4.7 5 1.1 3.7 0.06 6%

PRODUCT FEATURES AND OBJECTIVES OBJECTIVES The product objectives are based on the results of the customer surveys. They are a list of customer features that are taken into consideration when designing the Airflow Headlight. The following is a list of product objectives and how they will be obtained or measured to ensure that the goal of the project was met.

1. Waterproof 34% a. Material selection b. Clearance geometry c. Flow surface geometry 2. Amount of airflow 10% a. Material selection b. Flow surface geometry c. Flow surface finish 3. Ease of use 10% a. Ability to switch from headlight to airflow use in less than 2 minutes. 4. Appearance 9% a. Material selection

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b. Flow surface geometry c. Standard parts/components d. Reduced number of parts 5. Durability 8% a. Design factor consistent with loading conditions in expected use b. Rust-resistant material selection 6. Reliability 8% a. Allows a 35% increase in airflow into the intake 7. Ease of Installation 7% a. Can be installed using one standard tool b. Will take no longer than 45 minutes 8. Safety 7% a. Wiring in harness/ not exposed b. No sharp edges c. Meets SAE Ground Vehicle Lighting Standards 9. Versatility 7% a. Ability to fabricate into three headlight fixture configurations b. Ability to increase a minimum of 5 horsepower and 5 ft*lb of torque on a naturally aspirated motors c. Ability to increase minimum of 5 horsepower and 5 ft*lb of torque on a forced induction motors 10. Cost 6% a. Less than $500 retail

DESIGN CONCEPT DESIGN Originally, the concept behind this project was to create a design that could be quickly installed, utilized by the driver from within the vehicle, and obtain the maximum efficiency of the intake system to increase power and torque produced by the engine. Unfortunately, there were many draw backs to this concept idea; the largest of those being price. As seen in the calculations section, the maximum power gain from this product is not sufficient enough to allow a retail value of under $500. What is meant by this is that people have other avenues to increase the power of their vehicle, so this product needs to be effective as well as inexpensive. Other limiting factors include the orientation of the existing intake system and support structures within the engine bay of the vehicle which will be addressed in the fabrication section.

Before selecting the final design, several other concept ideas were drawn up. Based on the intended use of this project, there are only so many ways to go about modifying the headlight assembly to accommodate a streamline structure to allow for a smooth airflow into the intake system. The first idea was to utilize the design of a dual headlight system with LED lights that could accommodate for the missing headlamp. The headlamp in the center of figure 9 would be completely replaced by a funnel shaped structure and a cut out in the polycarbonate lens. A separate polycarbonate piece would be remolded to fit and seal the cut out hole. The issue with using this design is that the inlet flow area is too small and would not produce the

6 Airflow Headlights Nick Hardert desired increase in performance.

Figure 9 – Dual Headlight Concept

The second design, shown in figure 10, utilizes a similar idea as the above concept, except that the turn signal is removed from an OEM style headlight and replaced with LED lights to retain the functionality of the headlight. Unfortunately, the geometry of the headlight would not allow for LED lighting to fit alongside the funnel structure. Also, the structural supports on the front of the vehicle would not allow for a concept design of this nature, as seen in figure 11.

Figure 10 – Side Intake Inlet Concept

This section of the structure would need to be removed, severely weakening the structure.

Figure 11 – Front Structural support

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CURRENT DESIGN The current design utilizes the 4 inch x 6 inch parallelogram shape of the main headlamp area for maximum air flow. The funnel structure made of ABS plastic has a 4 inch diameter outlet that is secured into the main composite housing. The funnel structure has molded slots to allow for the headlamp assembly to lock into place. When in driving mode the opening for the airflow will be sealed by a ¼ inch polycarbonate piece with a rubber seal around its perimeter designed to lock into place.

Figure 12 – Current Design

CALCULATIONS STARTING PARAMETERS Before beginning the calculations, certain limits and assumptions were made to establish the parameters of the project; including, the average air velocity, maximum air velocity, ambient air temperature, density of the air, and the vehicle parameters. The vehicle being used to evaluate the product design is a 2003 Ford Mustang with a 3.8L, V6 engine that is rated at 190HP at 5,250 rpm and 298 Nm of torque at 2,750 rpm. Since the calculations directly rely on the performance parameters of the engine being tested the maximum velocity was based off the average speeds at the end of a quarter mile over ten runs, which is 92 mph. The average velocity is assumed to be 50 mph based on the average speed limits. However, in the Stress Analysis section the maximum velocity used was 200 mph to ensure the product could be used safely on faster, more powerful vehicles.

STRESS ANALYSIS The air funnel was analyzed to see if it could withstand the pressure of the incoming air during driving condition using Solidworks’s Finite Element Analysis software. The material of the funnel is ABS plastic, which has an ultimate tensile strength of 40 Mpa (13). The pressure used in the FEA was determined based on the maximum velocity of 200 mph or 89 m/s, which would produce a dynamic pressure of 4772 Pa. From figure 13, below, the highest stress point is 1,714,301.1 N/ or Pa, which means the product has a factor of safety of 25 due to the materials high ultimate tensile strength of 44 Mpa.

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Highest Stress point

Figure 13 – Static Pressure FEA

THE ASSEMBLY DESIGN DETAILS DISASSEMBLY The first step in fabrication was to disassemble the current passenger headlight in the vehicle, which can be seen in figure 14. The headlight breaks down into four main pieces, from right to left, the housing, the reflector, the inner housing, and the lens.

Figure 14 – Disassembled Headlight Once all the parts were separated the old sealant then needed to be removed from the main housing. Any cracks or defects found in the housing were repaired prior to fabrication of the final assembly.

ASSEMBLY Once the headlight assembly was disassembled the manufactured funnel and locking mechanism, produced by 3D printer, were cut, sanded, and surface treated. The Air Funnel, seen in figure 15, was cut to fit the curvature of the main housing using a pneumatic cut off wheel. then was sanded to remove rough surfaces around the edge of the funnel. The inside surface of the funnel was sanded with a range of sand papers to achieve a smooth surface. The surface was then primed and painted with a chrome finish spray paint. The sanding

9 Airflow Headlights Nick Hardert process was repeated with higher grit sand paper and then repainted. This process was repeated until the desired surface finish was achieved and a clear protective coating was applied. The locking mechanism was also sanded to achieve a smoother fit within the funnel.

Once the surface finish steps had been completed the funnel was secured into place using an adhesive. The adhesive chosen for this part of the fabrication is J-B Weld original epoxy. Figure 15 shows the orientations of the adhered parts.

Figure 15 – 3D Printed Components

The next step in the fabrication process was to cut the lens to create the opening for the air to enter through. To do this the shape of the inner housing was drawn onto the lens, seen in figures 16 and 17, and then cut using a pneumatic cut off tool using the blade shown in figure 18. The reason for using the special blade was to reduce melting of the polycarbonate lens material in order to retain the shape of the lens cut out, which will be reused as a removable cover.

Lens cut out

Figure 16 – Lens

Lens cut out

Figure 17 – Lens

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Figure 18 - Saw Blade

After cutting the lens the edges were sanded and the lens surface polished. The magnets, shown in figure 19, were attached to the inner housing and the polycarbonate piece that was cut from the lens. This allows the lens to be easily removed when needed. See appendix G for magnet specifications.

Figure 19 – Magnetic Lens

The next step in the headlamp fabrication was to reassemble the main housing with the inner housing and lens. This was done by applying a liquid silicone rubber to the inner groove of the main housing, aligning the inner housing and then attaching the lens to the main housing. Once together the assembly was clamped using duct tape and allowed to dry as seen in figure 20. Also the gap between the magnets and the lens were sealed with the liquid silicone rubber to ensure that water would not get into the cavity.

Figure 20 – Reassembly

Once the main assembly was together it was noticed that the light assembly, shown in figure 21, needed to be modified to fit within the main assembly. Since this part was removed from a previously manufactured headlight it is assumed that by shortening the distance between

11 Airflow Headlights Nick Hardert the light bulb and the glass lens it will no longer meet SAE J599 – Lighting Inspection Code. Due to the nature of this build, which is to prove the concept design, another lighting fixture was not used. In the occurrence that this design is manufactured the lighting assembly would have to be designed around the SAE standards for Ground Vehicle Lighting.

Figure 21 – Projector Housing

The modification to the projector housing is shown in figure 22. The structure holding the glass dome was cut and shortened approximately one inch. This allowed the assembly to fit within the main assembly. The light bulb used was also modified, shown in figure 23, to lock into the light assembly so that the light could be changed or removed.

Figure 22 – Light Assembly Modification

Figure 23 – Light Bulb Modification

Finally, the last fabrication step was to create the seal for the lens shown in figure 24. The seal was made from a liquid silicone rubber which was molded over the lens while in place to fill any gaps or void between the removable lens and the stationary one. The stationary lens

12 Airflow Headlights Nick Hardert was overlapped by ¼ inch to ensure water couldn’t wick under the seal. Once dry the removable lens was carefully removed leaving the final product as shown in figure 25.

Figure 24 – Final Assembly

Figure 25 – Removable Lens with Seal DRAWINGS Assembly, and detail drawings provide complete specifications for the product including material selection, geometric dimensions and tolerances. See appendix G for detailed drawings.

TESTING PROOF OF DESIGN The proof of design establishes the specifications that need to be met in order for the project to be successful. For this project the following improvements over the stock design must be met:  Allows a 35% increase in airflow into the intake  Ability to increase a minimum of 5 horsepower  Ability to increase a minimum of 5 ft*lb of torque  Waterproof

In order to prove these design requirements a series of tests were conducted, which compared the current intake design versus the new intake design. The two test procedures below where

13 Airflow Headlights Nick Hardert used to collect the data used to formulate the graphs seen in the results section. During both tests the following parameters where collected for both designs, using a Mac Tool diagnostic scanner: absolute throttle position percentage, engine rpm, calculated load percentage, mass air flow rate(lb/min), intake air temperature(°F) and vehicle speed (mph).

1. Street Test: A set range of 1500rpm-3500rpm was used to determine the mass air flow over the normal driving range of the vehicle. Increments of 500rpms collecting 30 data frames per rpm were used to gather a significant sample size. The vehicle was driven at each designated rpm for approximately 30 data frames, which range from 3- 5 seconds each.

2. ¼ Mile Test: The diagnostic scanner was started just before lining up with the Christmas tree on the drag way. After a short, 10 -15 second, delay the start signal was given and the vehicle was driven at WOT for approximately 16.9 seconds before reaching the finish line. A series of ten passes were used as a sample size As for the proof that the design is waterproof a dunk test as well as a spray test will be used to simulate rain conditions.

The design was also tested for its ability to stay waterproof during harsh conditions. This was tested by driving the vehicle in three rain storms for 30 minutes each and carefully inspecting the inside surfaces for any water accumulation after each test.

RESULTS According to the proof of design requirement, seen in the above section, the design was unsuccessful. The product was unable to meet the increase of 35% more air entering the intake as well as the increase in 5 HP and 5 ft*lbs of torque. However, by gaining the knowledge needed to accurately predict the design requirements while designing the product it is evident that the design requirements where unrealistic due to the nature of the design. With this in mind the product is seen as successful in increasing the performance of the vehicle. By looking at the graphs displayed below, it is evident that the throttle response is increased significantly over the range of 1500 rpm to 3500 rpm. This increase in throttle response allows the vehicle to accelerate more quickly with the given power rather than increasing the power of the vehicle to move it more quickly. Also, by looking at figure 29, below, it is evident that the design does increase the amount of air flow into the intake at a wide open throttle, but only by a 15% increase. The product was also successful in staying waterproof during several trial runs described above.

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Figure 26 - Mass Air Flow Vs RPM

Figure 27 - Mass Air Flow Vs MPH

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Figure 28 - Mass Air Flow Vs RPM

Figure 29 - Mass Air Flow Vs MPH

CONCLUSION

After testing the new headlight design, on and off the track, it is clear that the newly designed Air Flow headlight does in fact increase the amount of air entering the engine at a high rate of speed, while at wide open throttle. However, this increase is only 15% compared to the 35% requirement. Also, the graphs in the results section show that the product shifts the intake curve into a lower rpm range causing a decrease in throttle lag, thus allowing the

16 Airflow Headlights Nick Hardert vehicle to perform more efficiently. Overall, this project was a success even though the product was unable to meet the required increase in horsepower, torque and mass air flow. With a better understanding and more research on the performance of an engine design requirements could have been more accurately set for this project.

SCHEDULE AND BUDGET

The project schedule begins September 29, 2013 with concept development and spans over 30 weeks and ends April 23, 2014 with the submission of the final report to the University of Cincinnati Library. The project milestones for the project are listed in Table 2 below. The full schedule can be seen in appendix E.

Table 2-Project Milestones

Nick Hardert

Airflow Headlight

Oct 6 - 12-6 Oct 1319- Oct 2026- Oct 27Nov- 2 Oct NovNov-39 Nov1016- Nov1723- Nov2430- 7 -1 Dec 14-8 Dec 1521- Dec 2228- Dec 294 Jan- Dec 5-11JanJan Jan1218- 19Jan25- 1 26 JanFeb - 8 -2 Feb 15-9 Feb 1622- Feb 1 23 Mar - Feb 8 -2 Mar 15-9 Mar 1622- Mar 2329- Mar 305 Apr- Mar 12-6Apr 13-Apr 19 TASKS 29-Oct5 Sep Concept Development 16

Design 13

Material Procurement 13

Winter Report and Pres. 7

Fabrication and Assembly 16

Test and Modification 15

Tech Expo 3

Spring Report and Pres. 18

A budget of expenses documents all the costs associated with this project. All expected expenditures for this project are listed below and will be self funded. The total budget is expected to cover the cost of building a fully functioning prototype, which is projected to be $638.00.

Table 3- Project Budget

Material, Components or Labor Forecasted Amount Actual Amount OEM Headlight $100 $56 OEM Intake Silencer $75 High Flow Air Filter $50 $26 Projector Housing $50 $20 Rapid Prototyped Parts $210 $210 Silicon Seal $25 $0 Misc. Services/Parts $106 $20 Total $638 $332

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WORKS CITED

1. Brandson, John. techradar.com. [Online] [Cited: 10 08, 2013.] http://www.techradar.com/news/car-tech/how-computers-have-revolutionised-car-design- 1160141. 2. Engler, Brian. IHRA Certified Racer. [interv.] Nick Hardert. Cincinnati, 08 28, 2013. 3. Prewitt, Jake. IHRA Certified Racer. [interv.] Nick Hardert. Cincinnati, 08 31, 2013. 4. Rosner, paul. mustang5.0 and super fords . [Online] 08 01, 2008. [Cited: 10 08, 2013.] http://www.mustang50magazine.com/featuredvehicles/m5lp_0808_fox_mustang_drag_racer/ photo_01.html. 5. BRMSSupport. blue ridge motorsports. [Online] 24 06, 2010. [Cited: 10 08, 2013.] http://www.blueridgemotorsports.com/blog/page/20/. 6. Dave. The Throttle. [Online] 03 15, 2012. [Cited: 10 08, 2013.] http://thethrottle.thechive.com/2012/03/18/these-headlights-suck-air-16-pictures/headlight- intake-500-headlightintakecarbonnewwtmk/. 7. Dave, Roadster. ClubRoaster.net. [Online] 03 09, 2007. [Cited: 10 08, 2013.] http://clubroadster.net/vb_forum/20-exterior-sponsored-r-speed/5256-nb-headlight- intake.html. 8. forums.evolutionm.net. Decided make headlight duct. [Online] Oct 26, 2009. [Cited: 09 01, 2013.] http://forums.evolutionm.net/evo-show-shine/455035-decided-make-headlight- duct-2.html. 9. Sashasasha. North American Subaru Impreza Owners Club. [Online] 06 08, 2011. [Cited: 10 08, 2013.] http://forums.nasioc.com/forums/showthread.php?t=2194067. 10. Speed by Spectre. SpectrePerformance.com. [Online] [Cited: 08 31, 2013.] http://www.spectreperformance.com/index.php/catalog/air-intake-components/funnels- headlight-filter/intake-tube-headlight-funnel-aluminum-5-75-x-4-inlet.html. 11. Speed by Spectre. Spectre Performance.com. [Online] [Cited: 08 31, 2013.] http://www.spectreperformance.com/index.php/catalog/air-intake-components/funnels- headlight-filter/intake-tube-headlight-funnel-rectangular-abs-4-inlet.html . 12. PRweb. PR.com. The New Chevy Camaro Grille - More Than Just A Pretty Face. [Online] 07 24, 2012. [Cited: 08 31, 2013.] http://www.prweb.com/releases/2012/7/prweb9711848.htm. 13. RX7Club.com. Different twist on headlight modification? Airflow Specific. [Online] 04 20, 2009. [Cited: 08 31, 2013.] http://www.rx7club.com/2nd-generation-specific-1986-1992- 17/different-twist-headlight-modification-air-flow-specific-834319/. 14. Car ID. [Online] 2013. [Cited: 10 08, 2013.] http://www.carid.com/2012-chevy-camaro- grill/dj-grille-896337.html.

APPENDIX A - RESEARCH

Interview with Product Consumer: Brian Engler, experienced IHRA racer. 7075 Mulberry St. Cincinnati, OH 45239 08/28/13 He has 15+ years in competing in the International Hot Rod Association drag racing. Competitors would be looking for a design that fit their specific vehicle and that flows well with the rest of the car’s design. A manually operated device would be suitable but suggested to design an electrically operated door to close off the funnel. He mentioned that most race vehicles are taken by trailer to the track and are rarely driven at night. So this product would need to be marketed to a specific group of racers such as the Sportsman class racers. Important features to include: Ability to disengage, easily installed, waterproof, versatile, durable, cost effective (under $500.00 a set)

Interview with Product Consumer: Jake Prewitt, experienced IHRA racer. 3733 Lincoln Dr. Cincinnati, OH 45247 08/30/13 He has 9+ years in competing in the International Hot Rod Association drag racing. Competitors are constantly looking for ways to improve the air flow to their engines to give them an edge. Most racers tend to do this modification themselves do to the lack of products on the market. A product with some assembly/modifications required would not be a turn off. Most racers have built their vehicles themselves and would have some fabrication experience. He mentioned that he hasn’t seen a similar product on the market today. However, he pointed out a forum where enthusiasts were using fiberglass to design their own headlight fixtures to allow airflow to their air filters. Important features to include: Ability to disengage; filter for debris, waterproof, durable,

http://forums.evolutionm.net/evo-show-shine/455035-

decided-make-headlight-duct-2.html 09/01/13

Blog with consumers: “decided-make-headlight-duct” shunderwunder’s take on building an airflow headlight.

Well I keep getting requests for a write up so heres what I did. Sorry I wasn't planning to do a write up so There are no pics of the light dissassembled.

1. Remove & disassemble your light as per any headlight painting "How To" 2. Purchase some black door edge molding from an auto parts store. This may be hard to find since a lot of places only care it in chrome which you could use also if that floats your boat. 3. Place the inner housing behind the lens & either draw an outline of the area you want to cut or use fine line 1/8" tape to make the outline. I used the tape because it's easier for me. 4. Cut out the hole in the lens. Make sure you leave enough room to file down the rough edge left by the tool & still have enough lens for the molding to slide over. For this I used a Dremmel tool with a side cutter bit. It looks like a drill bit but it's designed to cut rather than drill holes. 5. Once you have rough cut the lens then use a file or sanding bit on the Dremmel to smooth out the edges. Go slow & be careful so that you don't take too much material away. 6. After you've smoothed out your cuts you should have a nice little window cut into your lens. Now is time to install the door edge molding. This stuff has some sticky stuff inside the grove & is pretty tight so it should hold itself in place pretty well. I started about midway down the inside edge heading toward the tight corner at the bottom cause this is the hardest place to get it installed & gives you plenty of room to work. This stuff is hard to install around corners & will fight you. I used a little bit of heat from heat gun to soften it up a bit & make it easier. Just don’t get it too hot. When you get back around to the starting point cut the molding leaving it a little long & then try to install. Trim small bits off till it fits perfect. 7. Now move on to the main headlight housing & remove the bulbs & the rubber boots that go behind the reflectors. 8. Take a marker & going in thru the hole in the back of the light mark a circle on the back of the high bean & fog reflectors with a sharpie that's about as big as the opening in the back of the housing. 9. Remove the fog light & High beam reflectors. They are kind of hard to get off the clips & I actually damaged my clips & glued the reflectors back into place. 10. Once the reflectors are out use the side cutting tool to cut out the area you've marked on them. The high beam reflector is plastic & will cut easily. The fog reflector however is metal & will take a while. 11. After cutting holes in the reflectors use your sanding bits to clean up the edges & make them nice & smooth. 12. Sand & paint the reflectors any color you want. I chose flat black. At this time you can also paint the inner housing if you'd like. 13. Drill a few holes in the bottom of the main housing. This will allow water to drain out since it is now an open headlight assembly. Make sure they are big enough to allow sufficient drainage but they don't need to be too big. 14. Blow out all parts & clean them as best you can. Pay special attention to the back side of the lens. 15. Reassemble your light as per any headlight painting "How To" & reinstall.

http://www.rx7club.com/2nd-generation-specific-1986-1992-17/different- twist-headlight-modification-air-flow-specific-834319/ 08/31/13

Blog with consumers: “Different twist on headlight modification? Airflow specific.”

A race enthusiast asked for help with a headlight design. He was making a fiberglass headlight cover with a scoop to let air flow toward the intake cone located directly behind his headlight. The blogger needed help with the electrical portion of the design. He wanted to have a switch operated servo to lift the headlight cover to allow for better flow. Suggested solutions given:  Hinge the headlight to a servo by welding new brackets inplace and running the wires through the firewall.  Use a headlight from a different modle car that is smaller. Mount the smaller headlight lower in the support bracket for the stock headlight. Then fabricate a scoop out of plastic for the remaining area that your stock headlight took

up.Finally rig up a switch that allows the headlight to raise in stages.

Headlight Funnel Round 5.75" W/4" Outlet Aluminum The funnel doesn’t allow for the use of the headlight it replaces. This product also doesn’t have a function that allows it to block water from entering your engine. http://www.spectreperformance.com/index.php/ Only made for cars catalog/air-intake-components/funnels- with round headlight-filter/intake-tube-headlight-funnel- headlight. aluminum-5-75-x-4-inlet.html 08/31/13 $24.99 USD

Application: Intake Tube Headlight Funnel Aluminum 5.75" X 4" Inlet

Features:  Fits vehicles with 5.75" round headlights  Polished aluminum finish  Designed to replace the high beams on vehicles with 4 round headlights  Includes adapter to allow direct installation with the factory headlight bezel  Use with p/n 97891 screen  Sold individually  Lifetime Warranty

Headlight Funnel Rectangular 4" Outlet ABS The funnel doesn’t allow for the use of the headlight it replaces. http://www.spectreperformance.co This product also m/index.php/catalog/air-intake- doesn’t have a components/funnels-headlight- function that filter/intake-tube-headlight-funnel- allows it to block rectangular-abs-4-inlet.html water from 08/31/13 entering your engine. Only made for cars with square Application: headlights. Intake Tube Headlight Funnel Rectangular ABS 4" Inlet $19.99 USD

Features:  Fits vehicles with rectangular headlights  6.5" wide x 4" tall with a 4" OD outlet  Used to run cold air through the headlight buckets where high beams are not needed  Factory trim ring holds funnel in place  Requires modification to the existing headlight bucket  Sold individually  Lifetime Warranty

Requires the DAC Predator Hidden Headlight Grille technology Falcon Ram Intake system to be effective. Only for the new Chevy Camaros. $1500 USD

http://www.prweb.com/releases/20

12/7/prweb9711848.htm 08/31/13 Features:  304 stainless frame.  D-shaped 30”-long opening, and a similar opening in the lower grille. The open area below the mesh grilles funnels cool air directly from the high-pressure area in front of the car into the radiator, lowering cooling system and under-hood temperatures substantially.  Easily-removable headlight doors.

APPENDIX B - SURVEY RESULTS AIRFLOW HEADLIGHT CUSTOMER SURVEY

This project will consist of building a functioning headlight capable of allowing air to flow directly into an engine’s air intake system. This will eliminate the need for holes cut in the front end of the car or removing the headlight to allow direct airflow into the air intake system. With your aid the survey will be used to weigh specific headlight operations and features. How important is each feature to you for the design of an airflow headlight? Please circle the appropriate answer. 1 = low importance 5 = high importance Averages Ease of Use 1 2 3 4 (3) 5 (7) N/A 4.7 Ease of Installation 1 2 3 (3) 4 (4) 5 (3) N/A 4 Low Cost 1 2 (2) 3 (3) 4 (3) 5 (2) N/A 3.5 Durability 1 2 3 (2) 4 (3) 5 (5) N/A 4.3 Reliability 1 2 3 (3) 4 (3) 5 (4) N/A 4.1 Versatility 1 2 (1) 3 (4) 4 (3) 5 (2) N/A 3.6 Waterproof 1 2 3 4 (3) 5 (7) N/A 4.7 Volume of Airflow 1 2 3 4 5 (10) N/A 5 Appearance 1 2 (1) 3 (3) 4 (3) 5 (3) N/A 3.8 Safety 1 2 (3) 3 (1) 4 (2) 5 (4) N/A 3.7 How satisfied are you with the current products on the market? Please circle the appropriate answer. 1 = very UNsatisfied 5 = very satisfied Averages Ease of Use 1 2 3 (3) 4 (4) 5 (3) N/A 4 Ease of Installation 1 2 3 (3) 4 (5) 5 (2) N/A 3.9 Low Cost 1 2 3 4 (3) 5 (7) N/A 4.7 Durability 1 2 3 (4) 4 (3) 5 (3) N/A 3.9 Reliability 1 2 3 (2) 4 (3) 5 (5) N/A 4.3 Versatility 1 (2) 2 (3) 3 (3) 4 (2) 5 N/A 2.5 Waterproof 1 (8) 2 (2) 3 4 5 N/A 1.2 Amount of Airflow 1 2 (1) 3 (2) 4 (5) 5 (2) N/A 3.8 Appearance 1 (1) 2 (3) 3 (2) 4 (3) 5 (1) N/A 3 Safety 1 2 3 4 (2) 5 (8) N/A 4.8 How long would you be willing to wait for a custom built airflow headlight? 1-3 Weeks (3) 3-6 Weeks (6) 6-9 Weeks (1) 9+ Weeks How much would you be willing to airflow headlight?

$50-$100 $100-$200 (3) $200-$500 (3) $500-$1000 (4) $1000-$2000

Please list any other important features that you would like in the airflow headlight.

APPENDIX C - QUALITY FUNCTION DEPLOYMENT (QFD)

Nick Hardert Airflow Headlight (fabrication) 9 = Strong 3 = Moderate

1 = Weak

Standard Parts Standard Components Standard Selection Material Edges Sharp No Geometry Clearnace Parts of Amount Reduced Geometry Surface Flow Finish Surface Flow Electronic Operation Standards Lighting Vehicle Ground SAE Meets importance Customer Satisfaction Current Satisfaction Planned ratio Improvement Importance Modified weight Relative % weight Relative Waterproof 9 3 9 3 3 3 4.7 1.2 5 4.2 19.6 0.34 34% Amount of Airflow 9 9 9 5 3.8 4.5 1.2 5.9 0.10 10% Ease of Use 9 9 3 3 9 9 3 4.7 4 5 1.3 5.9 0.10 10% Appearance 1 1 9 1 1 1 9 3 3.8 3 4 1.3 5.1 0.09 9% Durability 3 3 9 1 3 4.3 3.9 4.5 1.2 5.0 0.08 8% Reliability 3 3 9 1 1 1 1 3 4.1 4.3 5 1.2 4.8 0.08 8% Safety 9 1 9 3.7 4.8 5 1.0 3.9 0.07 7% Ease of Installation 3 9 4 3.9 4 1.0 4.1 0.07 7% Veratility 3 3 1 3 3.6 2.5 3 1.2 4.3 0.07 7% Low Cost 9 9 9 9 3.5 4.7 5 1.1 3.7 0.06 6% Abs. importance 2.06 2.27 7.30 0.98 2.23 4.83 3.00 2.26 1.09 2.06 28.1 58.5 1.0 1.0 Rel. importance 0.07 0.08 0.26 0.03 0.08 0.17 0.11 0.08 0.04 0.07 1.0

Engineering Characteristics Relative Importance Material Selection 26% Reduced amount of Parts 17% Flow Surface Geometry 11% Clearnace Geometry 8% Flow Surface Finish 8% Standard Components 8% Meets SAE Ground Vehicle Lighting Standards 7% Standard Parts (fabrication) 7% No Sharp Edges 3%

APPENDIX D - PRODUCT OBJECTIVES

OBJECTIVES The product objectives are based on the results of the customer surveys. They are a list of customer features that are taken into consideration when designing the Airflow Headlight. The following is a list of product objectives and how they will be obtained or measured to ensure that the goal of the project was met. 11. Waterproof 34% a. Material selection b. Clearance geometry c. Flow surface geometry 12. Amount of airflow 10% a. Material selection b. Flow surface geometry c. Flow surface finish 13. Ease of use 10% b. Operator has the ability to switch from headlight to airflow use. 14. Appearance 9% a. Material selection b. Flow surface geometry c. Standard parts/components d. Reduced number of parts 15. Durability 8% c. Design factor consistent with loading conditions in expected use d. Rust-resistant material selection 16. Reliability 8% b. Allows a 35% increase in airflow into the intake 17. Ease of Installation 7% c. Can be installed using one standard tool d. Will take no longer than 45 minutes 18. Safety 7% d. Wiring in harness/ not exposed e. No sharp edges f. Meets SAE Ground Vehicle Lighting Standards 19. Versatility 7% d. Ability to fabricate into three headlight fixture configurations e. Ability to increase a minimum of 5 horsepower and 5 ft*lb of torque on a naturally aspirated motors f. Ability to increase minimum of 5 horsepower and 5 ft*lb of torque on a forced induction motors 20. Cost 6% b. Less than $500 retail

APPENDIX E - SCHEDUELE

Nick Hardert

Airflow Headlight

Proof of Design Agreement 16

Concepts/Selection 16 29 3D Modeling 29 21 Design Calculations 8 12 Design Freeze 14 12 Bill of Material 11 20 Order parts 13 20 Design presentation 27

Fabrication 15

Assembly 16

Testing 22

Modification 1

Final Testing 20

Tech Expo 3

Project presention 11

Project Report 18

Library Submission 23

APPENDIX F - BUDGET

APPENDIX G - DRAWINGS AND PART SPECIFICATIONS