1268 replies to this topic

[Rosssco]

Surprisingly bijou pre-rad there Ed - Looks more efficient, but not much larger surface area than a 25-row oil coolers some use for Stage 2 SC'ers...

[Doctor Ed]

Its what PWR put together for a 400-450hp Porsche (and was taken off said car then given to me), it also ran a pissy little water pump, and had only short runs of 19mm hose. It's kindve a case of 'run what ya brung', i.e. That's what I've got, it cost bugger all, we'll just see if it works I'm making the lines to and from quite substantial, and it'll be easy enough to disassemble what's there and put a bigger rad in if/when needed. Hopefully I'll win a few points simply with the amount of flow I'll pump through it

Edited by ed.oates, 17 June 2016 - 01:47 PM.

[Doctor Ed]

Got a bit motivated today seeing as things here were getting close to finished

Basically had to chop part of the cooler mount out, and mold myself a small box section out of fiberglass. This box was needed so I had a flat surface to mount my DIY bulkhead hose mounts.

The bulkhead fittings are a flanged 25->20mm ID hose barb 90's. Quite a nice way of brining 25mm ID hose right up to the front, with 20mm hose completing only the last lengths to and from the core. The 25mm is supported by the bulkhead, and minimizes the need to bend such big hose around.

Fwiw, I've been experimenting with heat-forming the 20mm silicone hose. Essentially I found some 5 core heavy duty electrical cable that's about 18-19mm OD. Slip that up inside the hose, bend to shape, hit with a blowtorch till the hose sweats, and then submerge in cold water. It's a bit fun getting the cable back out, plus it's easy to heat things too far and singe the hose. Happy with how it turned out, but might try again just for OCD'ness.

[Doctor Ed]

not much larger surface area than a 25-row oil cooler

Just had a quick look at various 25row coolers... Core size seems to hover around 250x200mm. Core in mine is about 260x280. So actually nearly 50% more surface area when you look at the numbers. It's still small, agreed, hopefully it'll see enough air and water flow to work. If not, at the very least it'll get the car going, and leave me something to spend money on at a later date

[Mopeytitan]

very neat!! i like that a lot! ::

[Doctor Ed]

Well, the fat ass radiator is proving to be a royal PITA. The 56mm core leaves precisely fcuk all clearance to the front bulkhead and crashbox surface. I thought I had it sorted, but the IC rad just keeps on fouling in stuff. I'm down to the last few mm but I can't quite line up the rear bolts between the rad surround and the upper crashbox support flange. I've re-jigged the IC rad's mount, and it'll be close, but I suspect I'll need to modify/extend the crashbox support flange.

It also means my meticulously routed hosework has gone to crap. I can't run a 20mm hose around the side of the IC rad inside the support structure any more. There just isn't any room. So either I need to go to another IC cooler design (with inlet/outlet both on the same side) or I need to reroute a hose.

As I'm going to stick with the core I've got for now, it looks like I'll have a redundant bulkhead fitting And an ugly hose to contend with. On the upside, the ugly hose will be 25mm, thus the length of 20mm (along with one 90deg bend) will be reduced.

Fwiw, how the bulkhead fitting hoses looked fitted to my spare parts chassis:



I also started to fit up the heater core, bypass valve and pipework. I really need to get my sh*t together and get the pedal box and steering column in and finished, and this is the last little bastard holding that plan up. I'll make the cable activation linkage and mount tomorrow. Hopefully no surprises.

[/quote]

[Doctor Ed]

glory shot of the obnoxious orange brakes now put back together with ferodo ds2500 pads

[Bargi]

Mmmm orange Sent from my cuntyfuckbollock phone by Twatatalk

[Doctor Ed]

And rerouted coolant lines for the IC. Due to the core inlet/outlet positions, and the now shifted core position, I couldn't run the far outlet back to the bulkhead flange I made. So that hose now exits out the front of the support structure, and meets up with the bulkhead at the side.

As mentioned, it at least now has the benefit of being a run of 25mm hose with a 25mm elbow (instead of being 20mm). Not quite so neat looking, but, meh, needed to be that way.

[Crabash]

knew you would figure it out.

[Doctor Ed]

Well, the RHD dash was going in the bin anyway, and well, I had an E36 dash lying around...

[Nev]

I think you need to rename this thread to "Project Frankenstein" !

 

Keep the spanners turning, I am sure we all behind you

Edited by Nev, 24 June 2016 - 07:08 PM.

[Bargi]

Go on. Fit a Haltech https://youtu.be/GzLiGezXshk Sent from my cuntyfuckbollock phone by Twatatalk

[Doctor Ed]

Lol, this actually might fit, and the layout is bloody good!

[smiley]

Here's an lhd dash, once you come to your scenses.

http://www.regelin-p...gqqqpdvnrhb50v0

 

[Doctor Ed]

Compromise... I'll do both

[Doctor Ed]

And at the more mundane end of things... How I rerouted the 25mm cooler hoses to accommodate the new core position.

[The Batman]

why is your rad surround black and why doesnt it have the sides on it?

[Doctor Ed]

Because I cut them off and sprayed it black?

[Doctor Ed]

Heater bypass valve cable control sorted.

Due to the small throw of valve actuation lever assembly, I had to reduce the radius throw of the control arm. So a bit of dicking around, and one false start, and there we go. Ended up quite neat, moves well without slop, and the temp control knob travels just over 180deg, so fidelity is quite good given the small throw of the valve.