The Project Pad

Holy. Nice update. This is gonna be a beast

All_Euro wrote:Another awesome update - great work.

Done any test runs with the meth injection on your intake mani? Just curious about the depth of the meth bungs... seems like the conical spray would hit the sides before it reaches into the runners. I plan to inject w/m into my runners too - nothing fancy though, just drilling holes and threading them.

I will be doing testing prior to seam welding the intake manifold. the bungs have larger,counter sunk holes on the runner side. the depth of threadable bung is long for the 1/8" NPT nozzles. so if they aren't quite far enough into the runners I can send the tap back in and get them closer, so there wont be any spray on the side on the bung.

good looking out

UPDATE!!!!!
ok, back to the cooling system. I built a nice transition from the crackpipe to the remote thermostat return.



The remote thermostat will be plumbed in a manner that will get the thermostat itself a good warm water source while still allowing excellent from from the t-stat th the waterpump.

Welded




And here is the remote thermo housing installed.




The radiator outlet hose will be a nice easy bend to a 90 deg. fitting from the t-stat housing.

I still need to make some tabs to help support the crackpipe and remote t-stat

I also got a chance to get back into the AIR plumbing.


I got a lot of the vanjen flanges welded on, and some of the intake piping done, all the weds came out very clean with little to no, melt through. I went ahead and carbide cleaned and flapper drummed them nice and smooth.



I also added a small extension and bend to the compressor outlet to aid in clearing the hot exhaust manifold and Wastegate dump.


I also cleaned up the inside of the intake manifold plenum feed, with some 60/80 grit flapper drums.

MORE!!!
Ok back to this sexy exhaust manifold!!!
I picked up all of the individual runners from ryan. He welded all of the runners together except for the last elbow on the head or collector side, and has not yet welded the runners to the flange or collector. So I brought all of the pieces home and proceeded to reassemble/check fitment.


All told each runner shrunk about 1/8”. I know this is exact because the hot-side was welded to the inner fender and obv. would not bolt back together if it’s all tacked back up. So I slid a piece of 1/8” thick alu. between the manifold flange and hot-side flange and tightened it back up. Then it went back together like Legos hahaha.



Ryan had me tack on one runner for either side of the divided collector, to locate everything, but still allow him to assemble it as welded. This gives him good access to all sides of the runners as it comes together.


I also got to start the Wastegate dump in the front, once the second WG comes in I can merge the two outlets together and run a short 2.5” section back into the downpipe between the front halfshaft and the steering rods.

MORE!

AND ITS DONE!!!!!!!! Well sans EGT bungs anyway, but quite close



He welded one runner above then one below, and back and forth. END RESULT the head flange is flat to well under 0.01”!!!!!!!!

Dead flat.


And here it is re-installed on the head.




And DANG!! Ryan can put down a pretty sweet bead.

MORE!!
Here is the front Wastegate dump welded up and run back under the collector. The dumps will merge into a single 2.5” and then back into the downpipe





And booya!! 4” 180 bend in 304SS, its downpipe time!!!!

I found a few extra pics of the inside of the collector all cleaned up

and one of the wastegate outlet

Great update.

The manifold looks really nice, especially the profile in the collector after it was cleaned up.

Quick question, what type of thermostat is that and where did you get it? I assume this will replace the stocker.

lorge1989 wrote:Great update.

The manifold looks really nice, especially the profile in the collector after it was cleaned up.

Quick question, what type of thermostat is that and where did you get it? I assume this will replace the stocker.

thanks, tons of hours into the manifold!

the thermostat is a C&R racing unit, they are popular with the oval/circle track guys as well as a lot of cup cars.
I found it on ebay actually lol

there is NOOOO room for the stock assembly with the motor pushed down and back. its going to be tight with the steering arms, but we'll make it work

So I have put 0 thought into this but, if you ran a electric water pump controlled by thermostat, would you need an actual thermostat (of course you'd have some thermal circulation with the pump off).

Mcstiff wrote:So I have put 0 thought into this but, if you ran a electric water pump controlled by thermostat, would you need an actual thermostat (of course you'd have some thermal circulation with the pump off).

I spent a TON of time talking to the tech guys at Meziere, and it was their opinion that I should stay with a mechanical pump. basically citing that the car will be used for long road course sessions vs drag/show.cruise etc. we did talk about adding a "booster"pump to help cycle coolant in pits/waiting etc, which I will most likely do, as I can also purpose it as an after run pump as well



back to work on the old beast, update to come later

fancy machined parts
cooling system stuff
airbox and airbox feed

Finally got caught up on your progress, one update surpasses the next.

If you're willing to sell subframes, I may be willing to pay (well rear for sure lol)!

UPDATE!!!
Ok lets get caught up! Theres no way the stock thermostat housing / coolant sensor housing is ever going to fit with the motor pushed back.



I had this coolant “crack” pipe receiver made up to fit to my fabricated coolant outlet on the back of the head.

Haydn, drew up this piece and it will be getting machined shortly. It has a machined groove for the factory oring. It also has a nice smooth transition for the weld-els to be welded to.

UPDATE!!!
I wanted to make a nice and true, cold air intake for the turbo to draw from. I lost most of the early fabrication pics. The airbox is made from 0.065” 6061. I am running an AEM dryflow filter. It is the largest one they make, ~ 9” long x 6” dia. With a 4” inlet.

MORE AIRBOX!!!
Here is the feed to the airbox. I will be making a second top for the airbox for when the headlight is removed. More on that later.

The top is mounted by 4, m6 bolts.
The airbox is completely mounted on jegs silicone snapper grommets.

And a little more mockup for the airbox feed


And the airbox feed location




4” tube from the airbox to the turbo inlet

UPDATE!!!
In order to fit the airbox feed right where I wanted, I needed to make a new passenger side headlight bucket. Its fabricated out of 16 gauge mild steel. With some dimple dies and a lot of hammer work. It fits the back of the headlight with ½ - ¾” clearance, I’ll probably have to pop the headlight out to swap the high beam bulb, but that’s not big deal.

MORE!!!
I got the turbo drain line in place, I’m going to be changing it a bit to use a straight hose end for better clearance to the frame rail.




And the start of some breather cans


And the breather cans 3/8” NPT drain bungs

UPDATE!!!
My material finally came in for my radiator shroud, so it was time to get braking.

The shroud is 0.090” 5000 series alu, its soooo much nicer bender the 4-5000 grades of alu vs the 6061


It took a bit of time but I got the sides to fit very close to the sides of the end tanks.


I also had to relieve the shroud for the upper rad hose. And got a small plate welded in there.


The shroud still needs a bit of weld cleanup and some clip nuts for mounting but its nearly done.
And the 13” fan riveted on for temp fitment, now just waiting on the 8” fan. Then its time to cut out the fan holes and add some clip nuts.

MORE!!!
I also got back into the Wastegate outlet routing. The rear Wastegate will “loop” down and around to meet up with the front Wastegate outlet under the collector.


I got the merge for the outlets finished up and seam welded. This will dump back into the downpipe just above the front/pass CV and bellow the steering rods. I’ve run the steering and suspension through its range of motion and it’ll all clear just fine.
Just waiting on some 2.5” 304SS v-band flanges and a shorty 2.5” ID flex joint.


I need to change the front Wastegate outlet just a bit, I wanted better turbo drain line clearance.
And here you can see where the front outlet will meet up with the merge. The front Wastegate will have a second flex bellow and compact Tial clamp right before the merger.


And this pile of stainless will be a completed downpipe later this week! Woohoo