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Easy night tonight. Prepped the bottom bracket to be welded tomorrow. I used a smaller angled piece of aluminum and cut it to length. I drilled out a couple holes. 90 degree angle was not correct so the 90 was put into the clamp and turned into a 45ish. The aluminum was smashed flat with a hammer. It turned out fairly well when I placed it on the radiator. there's only a tiny gap. When we tack it up tomorrow, the 45ish will be squeezed tight to the bottom of the core support.
I keep calling the stock aluminum chunk a core support. I don't know the name for it other than it was used in conjunction with the core support. I'm winging names here, ok? lol Wow, I just received a text saying my Fragola shipment will be here tomorrow. Looks like I can wrap up the catch can and coolant system! https://bz7ylw.dm.files.1drv.com/y4m...&cropmode=none https://bz7vlw.dm.files.1drv.com/y4m...&cropmode=none https://bp7clw.dm.files.1drv.com/y4m...&cropmode=none https://bp7zlw.dm.files.1drv.com/y4m...&cropmode=none https://bp7alw.dm.files.1drv.com/y4m...&cropmode=none |
Last pic is a great shot. :tup: moving forward man. You better have this thing rolling for the Spring/opening of driving season meetup at my place.
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I probably should make a list of the next set of things to get done... I'm pretty sure you guys MIGHT have picked up on this... but I tend to go all over the place and I also go on extended tangents until I hit a mental stopping point where I feel satisfied/completed. The carbon fiber hood excursion was a pretty good example. lol. Well, TBH the whole build reflects my personality.... Didn't really think about that until just now. |
Welded up the bottom mount. My buddy did... I watched and learned. After he welded that up, wanted to fix how the top mount aligned with the bar. The top was slit and then I mashed the bar back with a hammer. after that it was welded.
The fittings came in so I doubled back to the house to pick them up and then came back to the shop to run the oil catch lines. Of course I ordered the wrong ORB fittings for the back of the breathers so I couldn't attach the whole thing like planned. The lines were wrapped up on the coolant, because that only needed one fitting (previously mentioned). The crash bar needs to come back off for a little grinding and paint... but it's pretty much done. I took some of the tape and plastic off so I could get some decent pictures. I've got to say, It was worth the extra efforts. https://a57blw.dm.files.1drv.com/y4m...&cropmode=none https://bp7ulw.dm.files.1drv.com/y4m...&cropmode=none https://a57clw.dm.files.1drv.com/y4m...&cropmode=none https://a57zlw.dm.files.1drv.com/y4m...&cropmode=none https://a57alw.dm.files.1drv.com/y4m...&cropmode=none https://a57vlw.dm.files.1drv.com/y4m...&cropmode=none https://a57ylw.dm.files.1drv.com/y4m...&cropmode=none https://a57wlw.dm.files.1drv.com/y4m...&cropmode=none https://bj7blw.dm.files.1drv.com/y4m...&cropmode=none https://a57ulw.dm.files.1drv.com/y4m...&cropmode=none https://bj7alw.dm.files.1drv.com/y4m...&cropmode=none https://bj7xlw.dm.files.1drv.com/y4m...&cropmode=none https://bj7tlw.dm.files.1drv.com/y4m...&cropmode=none https://bj7wlw.dm.files.1drv.com/y4m...&cropmode=none https://bj7ulw.dm.files.1drv.com/y4m...&cropmode=none |
Filled in a gap with metal instead of attempting to fill a large gap with weld. While setting up the crash bar in the vice I managed to slice my finger open. That's why I have a shop bandage on. Which is ironic, because I was grinding it for paint and so that it doesn't happen.
So the coat of paint is possible temporary because the crash bar will likely get powder coated. Also, I need to grind a few spots back to bare metal and weld tabs on for the air box to the radiator (eventually). Ordered a couple -12orb to -10an for my Motion Raceworks billet valve breathers. Also, 8 1/4NPT SS bungs are FINALLY coming for my EGT (exhaust gas temp) sensors. Those were ordered in February, covid messed up the supply chain big time for that. Speaking of what's not here... Remember when I ordered my K&N filters? Those are not here yet either. Oh well. Not sure if I said this before, but I've been waiting on Brian Tooley shaft mounted rockers. I need shaft mounted rockers to prevent deflection/movement on the pushrods. Well, if they don't come through... I'm going to order some of these. LS Series Chevy GM Casting Cathedral port I also need to order one more item for my engine too. Crank scraper w/ attached windage tray. Improved Racing has a great option. 3.622" Stroke LS, Vortec Engine Crank Scraper & Windage Tray Kit EGM-73X https://ap4pgq.dm.files.1drv.com/y4m...&cropmode=none https://ap4ngq.dm.files.1drv.com/y4m...&cropmode=none https://ap4ogq.dm.files.1drv.com/y4m...&cropmode=none https://ap4lgq.dm.files.1drv.com/y4m...&cropmode=none https://q50sgq.dm.files.1drv.com/y4m...&cropmode=none https://q50rgq.dm.files.1drv.com/y4m...&cropmode=none https://ap4kgq.dm.files.1drv.com/y4m...&cropmode=none |
If you tried to fill in that gap. Most likely it would have distorted. It can be done. Put a piece of copper behind it and use it for a back up bar. (The back up bar is to keep the puddle from falling out.) Then slowly weld a little and let it cool. And do it again.
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Is that your “Nookie” finger :ugh2:
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Checked on crash bar. I had to scuff and paint again. I hung the bar on forklift pegs for a respray. Coverage was way better this time.
Exciting stuff. Took longer to drive to the shop. https://cj5upa.dm.files.1drv.com/y4m...&cropmode=none https://bz52pa.dm.files.1drv.com/y4m...&cropmode=none https://cj5vpa.dm.files.1drv.com/y4m...&cropmode=none |
Turned out nice. :tup:
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So... I'm attempting to give some thought in next steps for my build. A few things came to mind:
Couple interesting items in there. I'm thinking of a way to mount the oil accumulator directly behind the v-mount, directly at the V or just above. It would be a short run of line and it would keep the weight low. Not that it weighs a ton, but all of it adds up! The Clearview filter needs to be mounted where the batter use to be. A trap door needs to be made so I can access the bottom side of the filter through the wheel well. The trap door will also keep the filter safe from being punctured. I have a Setrab oil cooler but I think it's going to be swapped for a CSF 8066 https://csfrace.com/csfs-new-line-of...l-oil-coolers/. The 8066 is 20" long so it will fit nice in the ducted area. It is now looking like a metal break is required for both the Clearview filter box and the air duct. Out of all those items. The very first thing that needs to happen is mounting for the A2W IC and cold side ducting. If my oil pan is done in the next month or so... this will all line up well. SO, that's the near future path... until it isn't. I can also skip back to the hotside once the bandsaw is operational (yes, still waiting on that). Also, I need a long electrical cord to lift my car on the hoist. Yeah, you read that right. That's a reason why my car has been stationary lower on the hoist. So all in all... the items listed are not that bad. It's clearly not a complete list of items either. Electrical w/ ECU needs to be completed. That will have a laundry list of sub items. The items in the bullet list are mostly in my possession. Random post... but aren't these all. |
You got a 220 outlet near the lift? I think I have a 10-12'ft 10awg cable with a plug on one end you can have.
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Man... I had the biggest day planned out. I bought a break, aluminum sheet, rivits/rivnut and sheers. I was going to get my airbox started.
Let me rewind a little. Yesterday I used some angle stock and flat stock to make a skeleton structure for the aluminum sheet. The flat stock was braised to the angle stock. That worked great. Today I wanted to add a bit more strength to the aluminum angle stock so I attempted to braise the square aluminum stock to the angle stock. That was a complete dud. I figured, "hey, this is a great time to TIG", it's in a hidden area. I used some scrap of the exact stock I was planning to weld up. I intentionally went hard on the amps in some areas and light in other areas. I felt comfortable enough to do my actual piece, so I did. The welds turned out good enough for my angle stock and square stock. The thickness of aluminum was different so I needed to start on the thicker material first and then move up to the thinner stuff. Near the end I was using a bit less filler rod. While welding the square stock to the angle stock, the braised aluminum piece fell off. That's fine. I really wanted to TIG it anyway. Well, Turns out the thin aluminum stock is a real bastard. Also, my welder started acting up near the end. I think the tungsten was contaminated. After about four solid attempts at getting the flat stock welded up, I threw in the towel. My needs were out pacing my skills. I needed my buddy's help to wrap up. Between getting the supplies and welding, my day of "getting stuff done" was reduced to getting supplies, welding one square stock to angle stock, welding one piece of flat stock and then not quite getting the other done. The direction is great... but man, my idea out pace my skills. Obviously I need practice. It is what it is. First couple pictures are my crashbar finished and mounted. https://bp50pa.dm.files.1drv.com/y4m...&cropmode=none https://bp53pa.dm.files.1drv.com/y4m...&cropmode=none https://bp52pa.dm.files.1drv.com/y4m...&cropmode=none https://bp5zpa.dm.files.1drv.com/y4m...&cropmode=none https://a552pa.dm.files.1drv.com/y4m...&cropmode=none https://a553pa.dm.files.1drv.com/y4m...&cropmode=none https://a550pa.dm.files.1drv.com/y4m...&cropmode=none https://a55zpa.dm.files.1drv.com/y4m...&cropmode=none https://bj53pa.dm.files.1drv.com/y4m...&cropmode=none https://bj51pa.dm.files.1drv.com/y4m...&cropmode=none https://bj5xpa.dm.files.1drv.com/y4m...&cropmode=none https://bj5vpa.dm.files.1drv.com/y4m...&cropmode=none https://az5upa.dm.files.1drv.com/y4m...&cropmode=none https://q511pa.dm.files.1drv.com/y4m...&cropmode=none https://q510pa.dm.files.1drv.com/y4m...&cropmode=none https://q512pa.dm.files.1drv.com/y4m...&cropmode=none https://ap5vpa.dm.files.1drv.com/y4m...&cropmode=none https://ap53pa.dm.files.1drv.com/y4m...&cropmode=none https://ap52pa.dm.files.1drv.com/y4m...&cropmode=none https://ap50pa.dm.files.1drv.com/y4m...&cropmode=none |
BTW, that angle stock that's bolted to the car is STRONG with the square stock welded inside. I think I could stand on it. The A2W intercoolers might have mounting at the front, which is why I needed something a bit thicker there.
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Yea..........................................you need some practice tig welding aluminum. Your welds look like someone blew their nose and snot came out and stuck to your metal. Don't expect it over night. It's going some time. Did you weld it on AC with argon gas?
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Welds were done with AC and Argon.
Yeah man, the square stock and angle stock came out good enough, it penetrated. The flat stock was atrocious. End of the day, it was still worth a try. It 100 percent makes me appreciate good welds. It's an art. Sent from my SM-G975U using Tapatalk |
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For aluminum. I use a mig gun at home. I have a Lincoln 180 Pro with the aluminum mig gun. I want a Lincoln Precision TIG 225 with a water cooled torch. Welding aluminum, the torch gets FVCKIN' HOT! |
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Wow, I found out why my last welds went from bad to impossible. The argon gas ran out... So yeah, that was a problem. I was getting so pissed at the end because I kept taking off the part, cleaning the metal, cleaning the tungsten, lightly grinding the metal and putting it back on just to keep shooting Zeus's lighting bolts at the flat stock murdering what I had JUST cleaned up.
The more you know. ORB fittings for the valve breathers were at the shop for over a week. Pretty cool... Those were put on and it was very gratifying, and it was such a simple thing too. Probably because the breather system is a completed system where as everything else is in the middle of incomplete. Best part was, that it was really simple to do. I needed that. Easy wins are welcomed every now and then. After that, the arts and crafts has begun for the air box. I'm starting with paper because it's cheap and easy. The sheets of aluminum I bought were 30 dollars a piece... maybe 25. Something like that. Point being... I don't feel like buying a whole bunch due to mistakes OR trying to flatten out a mistake. After everything is cut to shape (and figured out), the aluminum sheet will go on the underside of the flat stock. I'll then drill holes and rivet the aluminum together. The sides of the box will be held down with threaded rivets and screws. Well... that's what I'm thinking so far. Sometimes things change as I'm doing it. https://b55dag.dm.files.1drv.com/y4m...&cropmode=none https://b55gag.dm.files.1drv.com/y4m...&cropmode=none https://b55eag.dm.files.1drv.com/y4m...&cropmode=none https://b55bag.dm.files.1drv.com/y4m...&cropmode=none https://cj5gag.dm.files.1drv.com/y4m...&cropmode=none https://cj5fag.dm.files.1drv.com/y4m...&cropmode=none https://cj5iag.dm.files.1drv.com/y4m...&cropmode=none |
Metal gets $$$$$$ quick. Try pricing a sheet of 8'x4', 12ga. 316, 2B stainless..................$800.00. Someone wants me to do a project for them. Once I add up the material. I think they will change they mind.
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To add a comment to the aluminum welding. The running out of argon will definitly make a difference, but It looks like you are also doing a horrible job on cleaning the part. There's the stock stickers still on some of the pieces and adhesive under one of the welds. You need to actually clean it, with a wirebrush or abrasive that has not been used on stainless or mild steel. Then you need to scrub it with acetone or some type of aluminum degreaser.
It also looks like you are using too large of a filler wire maybe. Thats the only thing I can come up with for those globs. For aluminum the filler should basically be melted and jump to the puddle, if you are having to plunge it into the puddle you have too large of a filler. |
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My need of getting it done way out paced my skill set there. I'm ok with the glob welds considering where the bar is located. I think I'm going to cut the flat stock off and re do the section from the front of the radiator to the angle stock. Honestly, It's all learning to me and there have certainly been lessons learned. I'll get there, it just will be a bit painful off the get. The good news is that the aluminum stock used there wasn't terrible expensive. Thanks for the feed back man! Good to see a new name on the thread. |
Also when wire brushing aluminum. Use a stainless steel wire brush. Use it for aluminum only. If you use a carbon steel brush. It will leave rust marks in the aluminum after a few days. If you use a stainless steel brush that has been used on a different metal. It too will leave rust marks. The particles from the brush will imbed into the aluminum. That what causes the rust.
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IG@gbrettin
Re-do on the box frame. Used new aluminum that is wider and actually cleaned it properly with acetone this time. Most importantly, the weld was done with a full tank of argon as apposed to the tank running out. I couldn't figure out why my welds were not working at all last time. The more you know. ---------------------------------------------------------- https://cj5bag.dm.files.1drv.com/y4m...&cropmode=none https://cj5cag.dm.files.1drv.com/y4m...&cropmode=none https://cj4qag.dm.files.1drv.com/y4m...&cropmode=none https://cj5aag.dm.files.1drv.com/y4m...&cropmode=none https://bz5hag.dm.files.1drv.com/y4m...&cropmode=none |
I can't say last night was incredible productive. As always, something is better than nothing. I put the front clip on to get some measurements of the bottom of the tray and transferred the dimension to paper. Seeing the paper stock on the car helps visually so much. The paper cut out ended up being exactly the right measurement to the bottom of the bumper; but, I noticed rivnuts can be used to fasten the sheet if I extend the aluminum/paper 1". Actually, I may extend it a bit more than that so I can fold the metal back onto its self for strength. .... I need to look that up to see if that's a thing.
For grins, the A2W intercoolers were set in the position to mate up with the turbos and intake plenum. They fit perfectly there as an option. I might angle them upwards towards the plenum later. The big deal here is that there are options. TBH, I kind of like them flat. https://bp5dag.dm.files.1drv.com/y4m...&cropmode=none https://bp5fag.dm.files.1drv.com/y4m...&cropmode=none https://bp5cag.dm.files.1drv.com/y4m...&cropmode=none https://bp5bag.dm.files.1drv.com/y4m...&cropmode=none https://bp4qag.dm.files.1drv.com/y4m...&cropmode=none https://bp5aag.dm.files.1drv.com/y4m...&cropmode=none https://a55hag.dm.files.1drv.com/y4m...&cropmode=none |
Coming along :tup:
You gonna mount your water tank in the rear & plumb 3/4-1” cooler lines Up & through the intercooler? :ugh2: |
Yup. Water pump, 1" hose, heat exchanger and fill will all be in the rear. My buddy did the same thing on his car with zero issues. Besides, the front is getting cramped.
Sent from my SM-G975U using Tapatalk |
I find what you do is amazing, since that is not one of my skill sets..
keep up the good work.... :tiphat: |
It's coming together. :tup:
I'm in awe of someone that can cut straight lines with snips. I struggle with a radial arm saw..... :ugh2: |
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This is the first time I have done this. I wouldn't call this a skill set. My build is slow because I have to give thought to each component (and even mess-up after that). That's why I value all the feedback from people who have done items like this before. :tup: I have watched an excessive amount of YouTube DIY stuff and have been around when my buddy has hacked up their race car and then build something better. There's that. Hands on is wildly different. Since this is all pretty much new... I think that's why I take pictures, video and document everything. |
Did some measurements on the top corner of my air box. Looks like it will be a challenge. Eh, what's new.
I'm also looking to make a mount for my bumper so that it doesn't droop onto the crash bar/radiator mount. I'm going to try making a tab out of polycarbonate tab. The tab will be glued to the bumper and then that will slide into a slip on receiver. If that makes no sense... think of a trailer hitch and how that slides on. Same concept. I'm not really worried about locking it into place because there will be other spots for that using Quik-latch. Why not use a Quik-latch on the nose of the bumper? well, that would look odd IMO. https://ap5cag.dm.files.1drv.com/y4m...&cropmode=none https://ap4qag.dm.files.1drv.com/y4m...&cropmode=none https://q51hag.dm.files.1drv.com/y4m...&cropmode=none https://q51iag.dm.files.1drv.com/y4m...&cropmode=none https://q51dag.dm.files.1drv.com/y4m...&cropmode=none https://q51eag.dm.files.1drv.com/y4m...&cropmode=none |
Finished up the top air box. 9hours today getting it hammered out. I'm exhausted. Only thing not shown in the pictures very well is the seem filler I did at the end of the night. Let me know if you have any questions.
https://q51aag.dm.files.1drv.com/y4m...&cropmode=none https://q50qag.dm.files.1drv.com/y4m...&cropmode=none https://aj5iag.dm.files.1drv.com/y4m...&cropmode=none https://aj5dag.dm.files.1drv.com/y4m...&cropmode=none https://aj5gag.dm.files.1drv.com/y4m...&cropmode=none https://aj5bag.dm.files.1drv.com/y4m...&cropmode=none https://aj5cag.dm.files.1drv.com/y4m...&cropmode=none https://aj4qag.dm.files.1drv.com/y4m...&cropmode=none https://aj5aag.dm.files.1drv.com/y4m...&cropmode=none https://b56sjq.dm.files.1drv.com/y4m...&cropmode=none https://b56tjq.dm.files.1drv.com/y4m...&cropmode=none https://b56rjq.dm.files.1drv.com/y4m...&cropmode=none https://b56qjq.dm.files.1drv.com/y4m...&cropmode=none https://b56njq.dm.files.1drv.com/y4m...&cropmode=none https://b56mjq.dm.files.1drv.com/y4m...&cropmode=none https://cj6sjq.dm.files.1drv.com/y4m...&cropmode=none https://b56ljq.dm.files.1drv.com/y4m...&cropmode=none https://cj6qjq.dm.files.1drv.com/y4m...&cropmode=none https://cj6mjq.dm.files.1drv.com/y4m...&cropmode=none https://cj6pjq.dm.files.1drv.com/y4m...&cropmode=none https://bz6ojq.dm.files.1drv.com/y4m...&cropmode=none https://cj6ljq.dm.files.1drv.com/y4m...&cropmode=none https://cj6kjq.dm.files.1drv.com/y4m...&cropmode=none https://bz6qjq.dm.files.1drv.com/y4m...&cropmode=none |
Wrapped up the bottom sides of the box. I just need to fasten it down. The bottom side was supposed to be "easy"... at least that's what I told myself. One whole day was dedicated to making a template. It was pretty ridiculous. Working the aluminum only took a few hours by comparison.
I also snapped a picture of how the top was sealed up on the bottom side. After all the bends, rivets and mounting... the ducting is really strong considering how thin the sheets were. https://bj6sjq.dm.files.1drv.com/y4m...&cropmode=none https://bj6tjq.dm.files.1drv.com/y4m...&cropmode=none https://bz6mjq.dm.files.1drv.com/y4m...&cropmode=none https://bz6njq.dm.files.1drv.com/y4m...&cropmode=none https://bz6kjq.dm.files.1drv.com/y4m...&cropmode=none https://bp6njq.dm.files.1drv.com/y4m...&cropmode=none https://bz6ljq.dm.files.1drv.com/y4m...&cropmode=none https://bp6sjq.dm.files.1drv.com/y4m...&cropmode=none https://bp6qjq.dm.files.1drv.com/y4m...&cropmode=none https://bp6tjq.dm.files.1drv.com/y4m...&cropmode=none https://bp6ojq.dm.files.1drv.com/y4m...&cropmode=none https://bp6kjq.dm.files.1drv.com/y4m...&cropmode=none https://bp6ljq.dm.files.1drv.com/y4m...&cropmode=none https://a56tjq.dm.files.1drv.com/y4m...&cropmode=none https://a56sjq.dm.files.1drv.com/y4m...&cropmode=none https://a56qjq.dm.files.1drv.com/y4m...&cropmode=none https://a56kjq.dm.files.1drv.com/y4m...&cropmode=none |
I stabbed the last bit of rivets in today and then hooked everything back up for cold side plumbing. I was starting to get manic about the gaps today on the crash bar but decided I could easily tape everything off with foil tape, it's not like the cooling system will go in and out non stop... I hope not anyway. It can also be welded up a little down the road. To be honest, I feel like moving on to a different part of my build now. Two months was plenty working on the radiator and crash bar.
The end result does no justice to how much of a b1tch the process was. Looking at the pluming for the A2W... it looks like the piping will need to be an X so that there will be a common air supply between both banks. I think the placement of the A2W in the picture will be a similar placement. perhaps it will be kicked up at an angle. First thing that will happen is making a mount for the inter coolers. It certainly feels like I've already been down this road before... lol OH, one last thought. The -20 line will be converted to hard line. Current placement will be sawed through by the corner of the airbox. ONE final final thought... I burnt the absolute donkey p1ss out of my thumb. Melted plastic was still hot when I hit it with my thumb. https://q52njq.dm.files.1drv.com/y4m...&cropmode=none https://q52mjq.dm.files.1drv.com/y4m...&cropmode=none https://q52pjq.dm.files.1drv.com/y4m...&cropmode=none https://q52ojq.dm.files.1drv.com/y4m...&cropmode=none https://q52qjq.dm.files.1drv.com/y4m...&cropmode=none https://q52tjq.dm.files.1drv.com/y4m...&cropmode=none https://ap6pjq.dm.files.1drv.com/y4m...&cropmode=none https://ap6ojq.dm.files.1drv.com/y4m...&cropmode=none https://ap6rjq.dm.files.1drv.com/y4m...&cropmode=none https://ap6tjq.dm.files.1drv.com/y4m...&cropmode=none https://az6njq.dm.files.1drv.com/y4m...&cropmode=none https://az6mjq.dm.files.1drv.com/y4m...&cropmode=none https://bj6ljq.dm.files.1drv.com/y4m...&cropmode=none https://bj6kjq.dm.files.1drv.com/y4m...&cropmode=none https://az6tjq.dm.files.1drv.com/y4m...&cropmode=none https://bj6njq.dm.files.1drv.com/y4m...&cropmode=none |
Great pic. :tup:
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Good call on moving on to avoid the burn out.
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This probably wont come as a shocker to any of you.... but I'm already thinking of a version 2 vmount down the road. Going through the process, with anything, gives the hind sight adjustments. I'm thinking carbon fiber airbox that mounts into a a chromoly crashbar. Main point, I have something that will be functional now. Yes. I was 100% getting burnt out. I'm getting a surge of motivation for the next pats of the build. Well since I'm in the rambling mood. My low profile filters came in yesterday, :rofl2: I ordered them on Aug 3rd. Good thing I didn't need them! gesh. Here's my short list of what I want to work on next: 1: Clearview oil filter mounted and make list of fittings. 2: Mount A2W IC and start plumbing. 3: Start pulling fuel line. The Clearview needs will go where the battery use to be. I'll look into an access panel that can be welded in (yay! new skill put to use). Come to think of it... I can also break some metal to fit it too. I guess these skills come around in the long run. I'll keep my thread updated... Always do. Again, thanks for following this wild a$$ process. |
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