Dual-Scoop Shaker "How to go from Concept To Reality"

Since so many 'Shopped concepts go nowhere, I thought I'd put my first topic here, and show the mystery steps that get a 2D pic into a real-life object.

Moderators, if there's a preferred location for this topic, please act accordingly.

Now on with the show:


StudioMax render of a "shaker" style hoodscoop. The 3D model is 1:1 scale. Tubes shown here are 3"/76mm inside diameter. Planned build material is ABS plumbing pipe, and total estimated cost for the project is less than $100USD.


Designed to have "functional" throttle butterflies, it's main purpose will be to increase the "conspicuity" of my truck, thereby increasing SAFETY.
Yes, this is a piece of safety equipment.
In addition, it will scoop additional air onto the intake plenum, functioning as an air-to-air intercooler.
This is for a 2006 Chevy Colorado, but could be applied to pretty much any vehicle.

The 3D model looks workable, so let's move onto actual materials. Two 1-foot sections of 3" ABS pipe, and two 3" ABS, 90-deg bends. MANY pics to follow, make sure yer modem can breathe freely...  

So here's the actual parts made to match the CAD file's dimensions. The 90deg bends had their coupling flanges removed using the bandsaw.Bonded up with Oatey black ABS cement (yep, the stuff sold with the pipe, at the hardware store)and aligned perfectly, they were set aside to dry overnight.

Quick Shop Tip: Have more than ONE project going. That way, when one needs to be left alone, you can focus on the other. "Just walk away"...remember that line.


The hole template, printed at 100% size from the TurboCAD file. Placed according to measurements, and then adjusted to "eyeball".


This is what "Point of No Return" looks like. A Dremel with a reinforced cutting disk cut thru the body with disturbing ease.


That's daylight shining through.
A hacksaw blade made short work of the underlying braces. And no, the hood didn't suddenly collapse. So many armchair engineers were telling me it would. CAD said it wouldn't. -I like CAD.

Next: Mockup time.  

Everything fits up with no surprises, and the hood opens and closes without any contact. It clears with less than an eight inch at the top front of the scoop as it opens- as it did in the CAD file.


Head-on view. The hood pins? I graduated High school in 1980. Any other questions?


Parts for the butterflies. These will operate in synch with the fuel injection system, and appear to be throttling the engine as I drive.

Next: Paint and assembly.  

Simple,huh? Common screen-door type spring hold the unit securely, yet allow the dealer's techs to perform servicing with a minimum of head-scratching. throttle assembly is just mocked up here, we'll see the final arrangement in a bit.  

A trim was made on the CNC to hide the cut edges of the hood, and applied with 3M VHB tape.




Imagine THIS gasping in yer rear-view.

So how does it operate? First, a control circuit was dug out from The Google:

"P1" is a 50k trim pot. Instead of a knob, it'll get a fabbed arm attached. A flex cable from the gas pedal will pull the arm as the pedal is moved. A power supply fed from the truck's ignition will turn the circuit on as the engine is started.

A standard RC steering servo will be installed on the scoop, and hooked to the butterflies. The servo will open/close them as the signal instructs: The butterflies will move in perfect synch to pedal position/engine revs.


H:Two screws on the gas pedal's housing will be utilized for sensor assembly mounting.
J:screw added to pedal arm. A link from here will pull on the sensor arm.


The circuit and parts installed temporarily here. Confines under the dash prevent better photos of the assembly in situ.


The control assembly in test mode.
A:12V relay
B cell holder
Although these will last for months of use, they will be replaced with a 5v voltage regulator, and hooked to the RAP circuit on the Colorado, so the system automatically turns on/off.
C:12v input leads
D:fused power lead to sensor board
E:extended servo harness.
F:sensor board with circuit, rugged-ized with hot-melt glue
G:trim pot. An arm will be installed on this to detect gas pedal movement.
ALL parts are from the "goodie bin" and have been previously used in past projects. Recycle!

Short test video-servo operation