boosted300 Posted March 21, 2017 Author Share Posted March 21, 2017 Test fitting the bad dog rails... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 21, 2017 Author Share Posted March 21, 2017 Again….you are never complete until you modify your modifications… The frame rails are not “Bolt on” and we had to do some work to get them to fit right. Doug cut some additional grooves in the rails to allow them to flex and follow the curve of the existing frame rails toward the front of the car. Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 21, 2017 Author Share Posted March 21, 2017 Now to address the area most affected by rust. Once the area had been stripped and cleaned, we decided that the existing metal was just not up to snuff. So we decided to completely cut out the cancer. Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 21, 2017 Author Share Posted March 21, 2017 First cut from the bottom... Then drilling out the spot welds from the inside... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 We got some fresh sheet metal and Doug formed it into shape... matching it to the original piece... All done, and primed for welding the rails... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 While painting/undercoating would have been much easier, I decided to have the rails powdercoated... I taped up the edges to facilitate welding...the one on the left still has the tape in place... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 Test fitting... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 Welding them in...(while a fellow HybridZ watches in the distance) And for safe measure...some Eastwood internal frame rail coating... And a quick coat of Eastwood rubberized undercoating to finish it off... That project ended up being far more of a mission than we anticipated! But it had to be done. Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 Back to some more fun stuff... Because we put the condenser in, it meant that the McKinney intercooler would have to move forward a bit, however with the slope of the hood, the clearance was already next to nil...this would mean moving the intercooler down a bit as well, meaning the inlet and outlet would have to be cut and re-angled... Rather than go through that, I decided to go with a whole new unit. After measuring, re-measuring, measuring some more...and then measuring again (like 6 more times!) I came up with an overall size that I felt would work. I searched on the net extensively for an existing unit that would work, but I couldn't find anything I was happy with. I went at this for months while the other projects were being worked on until I finally decided to just fabricate a custom unit. For anyone who's ever done this you'll know what I mean when I say it's not nearly as easy as it sounds. Measuring, measuring, measuring, brainstorming, more measuring, experimenting...did I mention measuring? and changing directions and concepts at least 5-6 times. I went to Treadstone and experimented with all sorts of cores and end tanks looking for just the right combo... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 25, 2017 Author Share Posted March 25, 2017 (edited) After literally months of this...I decided to go with a core from Bell, and some customized end tanks. Now these days, the Chinese have changed the market producing almost anything for automotive performance at hard to believe prices. Entire intercooler systems can be had for $500-$600. I almost pulled the trigger on a CX Racing unit that was close to the specs I wanted...but just not close enough. Bell cores are not nearly as inexpensive...but I chose Bell not only because they make top of the line heat exchanger cores...but also because they do it in practically every size imaginable...literally. Call me crazy, but damn I don't know what it is about an aluminum heat exchanger that I find so sexy! I went with a core that was shorter than the Mckinney, but longer and wider to make up for it... Edited March 25, 2017 by boosted300 Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 30, 2017 Author Share Posted March 30, 2017 The wastegate flange that came on the tubular header was not only the wrong shape for the Tial, but we felt it was too small to effectively control the boost and would cause some creep. So what did we do? Modify the modification of course... We cut the existing flange off... And then carefully drilled out the opening for the new diameter tubing... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 30, 2017 Author Share Posted March 30, 2017 Test fitting the new piece With the new flange... Then Doug did some really nice additional prep work to the piece to shape it exactly like the existing tubing for optimal flow... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 30, 2017 Author Share Posted March 30, 2017 Test fitting the angle... Prepping the opening for welding... Just 'cause I think it's a cool pic... And finally cleaning up the welds... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted March 30, 2017 Author Share Posted March 30, 2017 (edited) Even though I loved the golden tint of the tubular manifold, I realized that 1.) it wasn't going to stay that color 2.) There would be a lot of heat generated by it, in a very confined space So I opted for Jet Hot coating that offered a nice middle ground of heat shielding and appearance. Edited March 30, 2017 by boosted300 Quote Link to comment Share on other sites More sharing options...
boosted300 Posted April 20, 2017 Author Share Posted April 20, 2017 End Tank rough drafts... Quote Link to comment Share on other sites More sharing options...
boosted300 Posted April 20, 2017 Author Share Posted April 20, 2017 A lot of views but no comments... Did I post in wrong board? Quote Link to comment Share on other sites More sharing options...
boosted300 Posted April 20, 2017 Author Share Posted April 20, 2017 Mocking up end tanks to measure fit and clearances... Quote Link to comment Share on other sites More sharing options...
seattlejester Posted April 20, 2017 Share Posted April 20, 2017 It would be rude to interrupt A friend and I were talking about wastgates the other day, kind of funny how how almost many manifolds have the wastage in the second to worst location, in addition they usually have additional routing after the branch point which almost puts it on par with the worst location/orientation. Must not be a problem if your fabricator with access and ability chose to do it that way, or was it done that way for packaging etc? Quote Link to comment Share on other sites More sharing options...
boosted300 Posted April 20, 2017 Author Share Posted April 20, 2017 It would be rude to interrupt A friend and I were talking about wastgates the other day, kind of funny how how almost many manifolds have the wastage in the second to worst location, in addition they usually have additional routing after the branch point which almost puts it on par with the worst location/orientation. Must not be a problem if your fabricator with access and ability chose to do it that way, or was it done that way for packaging etc? Since the manifold was not fabbed from scratch, we utilized the existing wastegate mounting point and then modified it to make the best of the situation. As with any budget, you gotta pick and choose your battles...some things I went balls to the wall on and others I opted to be more economical on. A hand-fabbed manifold would've been much pricier. I looked at some Raw Brokerage units and, while stunning works of art, they were much more expensive and they were designed for EFR's...which would have required even more $$$ for an EFR. The goal was to maximize what I had now (turbo, injectors, AEM 1) while improving peripheral items to handle future updgrades (Intercooler, cooling system, chasis). As far as routing the dump tube, there really aren't many options when you start squeezing this much stuff into a small space. We decided to try open dump first to as we weren't sure if there would be any creep. While I don't want to spoil the ending...I will say that it works like a charm (oh and feel free to interrupt...it's rewarding to be able to share and discuss with others who have the same passion!) Quote Link to comment Share on other sites More sharing options...
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