3D Printing Brake Cooling Ducts

[Mustangcol]

Good morning. I have installed a LVA front splitter on my Mustang non-PP. I would like to install the brembo brakes with proper cooling. I already installed the PP control arms with the air deflector to direct air at the rotors. So the car only needs the intake underneath and make a cut into the fender liner to direct air into the wheel wheel.

I was looking at NACA ducts, but I'm thinking that Ford's belly pan has been designed with an angle for a reason. So why reinvent it? I can easily create a .stl that can be 3D printed, and share the 3D file if anyone would like to make edits. This would be nice for anyone that wants to recreate this cooling without buying the expensive belly pan ($300+). You'd be able to 3D print the file and print a template to make the correct cuts, and epoxy it from the inside to make a smooth transition.

But I am in Colombia and it's impossible to find this belly pan without shipping 1 here. So this post is to see if anyone has 1 and can easily take measurements for me, and I'll get to designing it. I am an engineer and used Autodesk Inventor many years ago, I was crazy proficient with the program, so hopefully I haven't lost the skills, and I can quickly do it. Also don't mind if anyone needs other 3D printed parts designed. I did A LOT of this in university.

I have attached some photos from online.I can also get close to perfect dimensions if we take a photo of the belly pan, remove lens distortion with photoshop, and give me a few reference dimensions.

Sponsored

 

[Paul McWhiskey]

I have a ‘17 PP. the belly plate does not look like the top photo that you posted. The inlets to the deflectors look much more like the lower photo.

DM what dimensions you are specifically looking for and I will be happy to provide them to you.

 

[HeelToeHero]

I've done some printing to make up new larger deflectors on the control arm.

 

[Mustangcol]

I have a ‘17 PP. the belly plate does not look like the top photo that you posted. The inlets to the deflectors look much more like the lower photo.

DM what dimensions you are specifically looking for and I will be happy to provide them to you.

I'll get back to you. I've been looking online at different set ups people have. I really need to get it on a lift and make a game plan. It looks like the 2015-2017 has smaller outlet to the brakes, and 2018+ they enlarged them significantly. Maybe just 3D print a large vent and go for it.

 

[Mustangcol]

I've done some printing to make up new larger deflectors on the control arm.

Thats nice. Do you mind sharing the STL? My email is [email protected]

 

[Mustangcol]

I may be on to something. I sent a message to FS performance about the brake cooling ducts on their splitter. I asked if they can sell me only the brake cooling ducts and he replied, yes, $95 shipped. I asked him for dimensions and I'll measure my car when I install the K-member brace, maybe it will work. I think it's a easy solution:

https://www.fsperformanceengineerin...2017-performance-package-gt-front-splitter-v1

 

[Therealmattlex]

I've done some printing to make up new larger deflectors on the control arm.

Did you notice a difference in brake cooling with the new ones?

 

[HeelToeHero]

Thats nice. Do you mind sharing the STL? My email is [email protected]

Sorry for the delay, DM sent.

 

[HeelToeHero]

Did you notice a difference in brake cooling with the new ones?

Yes, and larger deflectors have been tested and proven to be effective by some companies as well.
My next project is to develop something for the rear brakes which could use a bit of cooling.

 

[abatman]

Sorry for the delay, DM sent.

Do you mind sending me the file as well? I've been using the Porsche GT3 deflectors but want to switch to a mustang specific setup

 

[NGOT8R]

I know this thread is about brake cooling, but what about some 3D printed cooling ducts that can be riveted in place of the areas highlighted in green to serve as a source of fresh air to keep engine bays cooler.

I like this idea for a top mounted single turbo. I can see this as being beneficial to keeping heat at bay and forcing it out the back of an open cowl hood.

 

[Mustangcol]

I know this thread is about brake cooling, but what about some 3D printed cooling ducts that can be riveted in place of the areas highlighted in green to serve as a source of fresh air to keep engine bays cooler.

I like this idea for a top mounted single turbo. I can see this as being beneficial to keeping heat at bay and forcing it out the back of an open cowl hood.

I started working on a 3D model to 3D print. I have the LVA splitter so its flat underneath. With the model, I can print a template to help with making the cuts and then this slides in above and is installed with epoxy so its 100% flat underneath, no screws. The intention is to install at 15 deg so it further helps direct airflow to the rotors. I don't know when I'll be able to take measurements, I have to first wait for my GT500 style diffuser to arrive and find a good exhaust shop to line up my 2018+ active mufflers that i installed on my 2017.

I would have to confirm the dimensions, but the outlet is angled because 1. the entire inlet is angled and don't want to spend many hours creating a perfect model and 2. from pictures i've seen online, it looks like the 15-17 and 18-23 belly pans also are designed like this. I'm open to suggestions. Don't mind sharing the STL

EDIT: this would be the passenger side. To create the driver side, I only need to mirror it in the program.

 

[ihasnostang]

i have a scanner but i only have the PP belly pan with the normal shaped ducts

 

[Mustangcol]

i have a scanner but i only have the PP belly pan with the normal shaped ducts

It would be interesting to see a CFD analysis of the OEM belly pan and a proper duct like what I have designed. I imagine that the OEM belly pan is restricted by manufacturing of the pan. In other words, it has to be easily removed from the mold and therefore has compromises in the design. But I haven't given this much thought.

I'm just thinking, high air pressure underneath, create a path to the rotors, and have the outlet properly sized because I imagine there is diminishing returns in cooling, not large enough scoop on the control arm, and limit to how much air can pass through the rotor. Extra air would be more drag with air being trapped in the wheel well. And also, having the proper quantity cooling for the intended use. I would be lucky to have time to go to the track, so this is just for all the mountain roads I have here.

 

[Mustangcol]

I started googling some research papers about cooling on rotors and you can get lost on this topic. There is a lot of information. I'm just going to make the outlet of the brake duct to be a little larger than the deflector on the control arm haha. That should be enough for my use. But if you wanted to use a larger deflector like Vorshlag, I would recommend making the outlet a little larger than the surface area of the Vorshlag deflector

Sponsored