R/TErnie's Evo 9 2.2L 4G64 EFR7670
I used the one above from Pegasus on the FSAE cars for the past few years and I really like them.
I'll call Tony on Monday...I have other things to bug him about anyway.
Hey thanks man! I appreciate you buying my head gasket... helps me continue on the car.
I'm wrapping up all my loose ends, and in doing so looking for weight in a few obvious places. I'll write more about it when I post up some pictures. but I do know I need to be at 2900 pounds with driver, which may be a bit out of my reach right now, but we'll see once I get it back on the scales and really start attacking the weight.
I'm wrapping up all my loose ends, and in doing so looking for weight in a few obvious places. I'll write more about it when I post up some pictures. but I do know I need to be at 2900 pounds with driver, which may be a bit out of my reach right now, but we'll see once I get it back on the scales and really start attacking the weight.
Last edited by R/TErnie; May 22, 2012 at 11:15 PM.
Update!
So I've been working pretty diligently on the car this past weekend so I figured I would post up some of the progress. Sometimes it's slow going because I take too much time looking at all the options and figuring out which configuration will have the least amount of compromise. This will make me stare at the car for 30 minutes with parts/material/tubing in my hands looking dumb. Eventually I make a decision, turn the music up, and get to making loud noises.
Most of the progress is with the downpipe, dumptubes, FMIC, and IC piping routing.
Dumptubes. I wanted them to be long enough to dump under the starter and past the OEM heat shield, so that it would still be effective. I also wanted them to be somewhat symmetrical. I almost ran out of 1.75" tubing, but found some 18 gauge tubing left over from a previous project. I was very happy!
Of course to make the dumptube I had to cut the collector opening in the manifold, shape the piece that welds the v-band wastegate flange to the collector... then weld it all together. I put some extra attention to this particular weld. After my previous test fits I noticed that the gate was pretty close to the downpipe (the top hat) so I opted to make the wastegate flange sit closer to the collector to give me more room. Here it is without the downpipe on.
Downpipe - So this took me a bit of time and I messed up a few times after I had it made PERFECTLY. So I tacked it all together previously and had some of it welded out. Well after trying to install it a few times with NOTHING in the car I found it nearly impossible. So I decided to break it up into 2 pieces... so in the end I have an "o2 housing" with out an o2 sensor in it. I removed the analog input from the narrow band and replaced it with an IAT sensor that I'll either put in the hot side of the intercooler or the intake pipe... just to have more data.
So when I had it tacked together it fit perfectly under the car. After looking at how long my flex pipe is and how wide it is... I decided that the best place for it would be locating it directly under the oil pan.
So the v-band section adds an inch of pipe length in the z-axis. So I cut out .750" to get it back where it needs to be, and then tacked the flex pipe on. I ended up making the flex pipe a little too close to the pan (read: touching) so I had to break the tacks and slip the v-bands a little further down on the tubing...gave myself some extra room. re-tacked the flex pipe to orient it properly and then got jiggy with welding it. Backpurged it for ****s and giggles. Turned out well.
This one shows how it packages relative to the radiator. Notice the v-band threads protruding from the downpipe v-band section? That clamp got rotated out of the way. I'll probably end up flipping it and rotating it out of the way.
I think these are just pictures I took once I had it together at one time...before I took it apart for the 11-billionth time.
Intercooler Part IV?
So I've been holding off on mounting the intercooler or welding on the end tanks because I wanted to make sure I didn't limit myself with packaging the turbo system. So I dusted off these guys.
Vertical shot on the passenger side of the intercooler core. This just shows the room I have between my new bumper support and the core. The end tanks fit within this space very well.
This shows my pain in the rear power-steering lines. I hate these things. I need to re-fabricate these and put them somewhere where the don't bother me.
Remember how I said I hold tubing and stare? Yeah I held these for a long time before cutting them.
This is the mount that mounts the IC to the radiator core support. This took not too much time to make. It uses the OEM rubber grommet
Makes for a super nice install. It took me a while to place the intercooler based on it's relative height to the radiator core support. Once I had that hammered out... ZAP! - and then it was.
Passenger side end tank got located, fit, and zapped.
My tube that I looked at for too long. Here it is completed. Shows the kick up before the tube enters the end tank. The end tank I cut the hole with a hole saw and then used my carbide to shape it to match the tube. And of course I did this before I welded the end tank to the core!
More zappage. And it was.
These two shots show the outlet pipe. Yes it's low, but shockingly my previous intercoolers were fitted just as low... so why not get rid of the extra ic piping and use of extra space up front? I can use that space for brake ducts or something cool.
I've been looking at this for more than an hour. The start of the LICP. It hasn't progressed much. Kind of a sore subject.
Tacked the inlet pipe.
More Zapping and Buzzing. I also did the other side... straight shot. Goes under the radiator and under the 4" intake pipe. lots of room for a coupler. Worked out like a champ. Has the same up-turn on the pipe as it exits the endtank.
Test fit (seems like that's all I'm doing these days)
Remember that time when I said that I needed to clock that clamp? I think I did that here. I think I got tired of staring and did something.
Brackets/Mounting Tabs for Intercooler - I used the OEM bits again. Turned out nicely. Random shots of it.
Finally... Intercooler completed.
Up Next is the battle between the FMM and the LICP. I think I'm going to fabricate the FMM first so that I know how much room I have for the LICP and just make the mount as compact as possible. Starting to think about ideas for quick and easy... and then started thinking about lightweight. I'm pretty sure I'm going to try an aluminum welded mount. We'll see how butter welds hold up to 650whp launches. Time to do some real welding!
After that... I'll be doing some wiring for the trunk mounted battery. Need to order the kill switch finally. I'll make up my mind tomorrow. T1 has a really cool compact kill switch solution. I may pull the trigger and support Tony and Mike. For now here's my Audio store pickup.
Ordered more ss tubing for the ACD hardline... ordered a black straight coupler for the LICP to FMIC coupler. the Humped couplers I have won't fit under there...or at least I assume. I can fit my finger between the pipe and the core support. I'll need to think about this some more.
I called ATP (who makes the heat shields...not atpturbo) and got a quote for an Inco heat shield for my turbine housing. Deals! I'll probably send them my turbine housing when I send everything else out to be coated. I guess that makes sense...
I'm also looking at buying a small shear, brake, and roller for doing my air box and heat shielding. Grizzley has a cheap 36" unit. I might also just make a v-block and use my 10 ton press I already have.
I've also been contemplating running QTP's with 16" RX7 wheels. will cost me about 1100 complete to get those. If I run my RE01Rs (245/45/17) on the BBS wheels then I have some good dyno wheels/burn up tire/street wheels. And then I can leave my R888's or Hoosiers on my CCW's for "fun wheels" I think having 3 sets of wheels is the most logical (or illogical?) Hard to explain that to the wife right? I need 3 sets of wheels... and 2 cars. HA!
I'm looking at dry carbon trunk lids. Robi and Velocity Carbon have my Eye. I'll see what kind of deal I can work out.
Also looking at aluminum 2pc driveshafts. There is a local place I'll visit and see how much they can make me a shaft for. Otherwise Dave B might get to take my money.
I'm designing a chromoly rear diff supports that use the OEM bushings. I have the Beatrush additional bushings, and that's all the more noise I want to hear out of that diff. Should save a few pounds and take a few hours.
I'm planning on removing the door braces from the rear doors. I'll be sure to document that one.
Looking at going to a Lithium 4-5 lb battery. Couple good options right now. Just watching budget.
The rear engine mount needs to be re-fabricated to be lighter. I saw an AMS prototype somewhere and it was super simple, and slightly more rigid than stock. I'm going to steal their design and make it happen. I believe it was in their Time Attack build thread. Thanks guys!
Other than that... just tinkering away. I made some killer Lasagna tonight, ate dinner, and then fell asleep for 3 hours. Woke up and couldn't go back to sleep. So I figured what better way to burn a few hours!
As always, have nice day.
So I've been working pretty diligently on the car this past weekend so I figured I would post up some of the progress. Sometimes it's slow going because I take too much time looking at all the options and figuring out which configuration will have the least amount of compromise. This will make me stare at the car for 30 minutes with parts/material/tubing in my hands looking dumb. Eventually I make a decision, turn the music up, and get to making loud noises.
Most of the progress is with the downpipe, dumptubes, FMIC, and IC piping routing.
Dumptubes. I wanted them to be long enough to dump under the starter and past the OEM heat shield, so that it would still be effective. I also wanted them to be somewhat symmetrical. I almost ran out of 1.75" tubing, but found some 18 gauge tubing left over from a previous project. I was very happy!
Of course to make the dumptube I had to cut the collector opening in the manifold, shape the piece that welds the v-band wastegate flange to the collector... then weld it all together. I put some extra attention to this particular weld. After my previous test fits I noticed that the gate was pretty close to the downpipe (the top hat) so I opted to make the wastegate flange sit closer to the collector to give me more room. Here it is without the downpipe on.
Downpipe - So this took me a bit of time and I messed up a few times after I had it made PERFECTLY. So I tacked it all together previously and had some of it welded out. Well after trying to install it a few times with NOTHING in the car I found it nearly impossible. So I decided to break it up into 2 pieces... so in the end I have an "o2 housing" with out an o2 sensor in it. I removed the analog input from the narrow band and replaced it with an IAT sensor that I'll either put in the hot side of the intercooler or the intake pipe... just to have more data.
So when I had it tacked together it fit perfectly under the car. After looking at how long my flex pipe is and how wide it is... I decided that the best place for it would be locating it directly under the oil pan.
So the v-band section adds an inch of pipe length in the z-axis. So I cut out .750" to get it back where it needs to be, and then tacked the flex pipe on. I ended up making the flex pipe a little too close to the pan (read: touching) so I had to break the tacks and slip the v-bands a little further down on the tubing...gave myself some extra room. re-tacked the flex pipe to orient it properly and then got jiggy with welding it. Backpurged it for ****s and giggles. Turned out well.
This one shows how it packages relative to the radiator. Notice the v-band threads protruding from the downpipe v-band section? That clamp got rotated out of the way. I'll probably end up flipping it and rotating it out of the way.
I think these are just pictures I took once I had it together at one time...before I took it apart for the 11-billionth time.
Intercooler Part IV?
So I've been holding off on mounting the intercooler or welding on the end tanks because I wanted to make sure I didn't limit myself with packaging the turbo system. So I dusted off these guys.
Vertical shot on the passenger side of the intercooler core. This just shows the room I have between my new bumper support and the core. The end tanks fit within this space very well.
This shows my pain in the rear power-steering lines. I hate these things. I need to re-fabricate these and put them somewhere where the don't bother me.
Remember how I said I hold tubing and stare? Yeah I held these for a long time before cutting them.
This is the mount that mounts the IC to the radiator core support. This took not too much time to make. It uses the OEM rubber grommet
Makes for a super nice install. It took me a while to place the intercooler based on it's relative height to the radiator core support. Once I had that hammered out... ZAP! - and then it was.Passenger side end tank got located, fit, and zapped.
My tube that I looked at for too long. Here it is completed. Shows the kick up before the tube enters the end tank. The end tank I cut the hole with a hole saw and then used my carbide to shape it to match the tube. And of course I did this before I welded the end tank to the core!
More zappage. And it was.
These two shots show the outlet pipe. Yes it's low, but shockingly my previous intercoolers were fitted just as low... so why not get rid of the extra ic piping and use of extra space up front? I can use that space for brake ducts or something cool.
I've been looking at this for more than an hour. The start of the LICP. It hasn't progressed much. Kind of a sore subject.
Tacked the inlet pipe.
More Zapping and Buzzing. I also did the other side... straight shot. Goes under the radiator and under the 4" intake pipe. lots of room for a coupler. Worked out like a champ. Has the same up-turn on the pipe as it exits the endtank.
Test fit (seems like that's all I'm doing these days)
Remember that time when I said that I needed to clock that clamp? I think I did that here. I think I got tired of staring and did something.
Brackets/Mounting Tabs for Intercooler - I used the OEM bits again. Turned out nicely. Random shots of it.
Finally... Intercooler completed.
Up Next is the battle between the FMM and the LICP. I think I'm going to fabricate the FMM first so that I know how much room I have for the LICP and just make the mount as compact as possible. Starting to think about ideas for quick and easy... and then started thinking about lightweight. I'm pretty sure I'm going to try an aluminum welded mount. We'll see how butter welds hold up to 650whp launches. Time to do some real welding!
After that... I'll be doing some wiring for the trunk mounted battery. Need to order the kill switch finally. I'll make up my mind tomorrow. T1 has a really cool compact kill switch solution. I may pull the trigger and support Tony and Mike. For now here's my Audio store pickup.
Ordered more ss tubing for the ACD hardline... ordered a black straight coupler for the LICP to FMIC coupler. the Humped couplers I have won't fit under there...or at least I assume. I can fit my finger between the pipe and the core support. I'll need to think about this some more.
I called ATP (who makes the heat shields...not atpturbo) and got a quote for an Inco heat shield for my turbine housing. Deals! I'll probably send them my turbine housing when I send everything else out to be coated. I guess that makes sense...
I'm also looking at buying a small shear, brake, and roller for doing my air box and heat shielding. Grizzley has a cheap 36" unit. I might also just make a v-block and use my 10 ton press I already have.
I've also been contemplating running QTP's with 16" RX7 wheels. will cost me about 1100 complete to get those. If I run my RE01Rs (245/45/17) on the BBS wheels then I have some good dyno wheels/burn up tire/street wheels. And then I can leave my R888's or Hoosiers on my CCW's for "fun wheels" I think having 3 sets of wheels is the most logical (or illogical?) Hard to explain that to the wife right? I need 3 sets of wheels... and 2 cars. HA!
I'm looking at dry carbon trunk lids. Robi and Velocity Carbon have my Eye. I'll see what kind of deal I can work out.
Also looking at aluminum 2pc driveshafts. There is a local place I'll visit and see how much they can make me a shaft for. Otherwise Dave B might get to take my money.
I'm designing a chromoly rear diff supports that use the OEM bushings. I have the Beatrush additional bushings, and that's all the more noise I want to hear out of that diff. Should save a few pounds and take a few hours.
I'm planning on removing the door braces from the rear doors. I'll be sure to document that one.
Looking at going to a Lithium 4-5 lb battery. Couple good options right now. Just watching budget.
The rear engine mount needs to be re-fabricated to be lighter. I saw an AMS prototype somewhere and it was super simple, and slightly more rigid than stock. I'm going to steal their design and make it happen. I believe it was in their Time Attack build thread. Thanks guys!
Other than that... just tinkering away. I made some killer Lasagna tonight, ate dinner, and then fell asleep for 3 hours. Woke up and couldn't go back to sleep. So I figured what better way to burn a few hours!
As always, have nice day.
Wow, your fab work is beautiful! That intercooler looks great, I love the end tanks. Everything looks so smooth. I love that you put the extra attention to detail into thinking the project through and the overall design minimizing the compromise. So many times you see an amazing manifold and then the "Oops, I forgot about having to fit a downpipe I'll just cheat the ever living hell out of this bend so that it will clear." Absolutely fantastic craftsmanship and design!
Thanks guys. Video will be awesome. My buddy Justin has some serious video equipment! Hopefully we'll get to make a cool video for it.
Got my Kill switch from Tony today! Super stoked about this. I'll be sure to show how it installs and why it's super badass. T1 Race Battery kill switch.
http://www.t1racedevelopment.com/ind...utoff-kit.html
Got my Kill switch from Tony today! Super stoked about this. I'll be sure to show how it installs and why it's super badass. T1 Race Battery kill switch.
http://www.t1racedevelopment.com/ind...utoff-kit.html
