Cerberus Part II!
 

Okay so TTT wanted to see what I've been doodling with for awhile, so I'll post up some pictures. They're just pictures for right now. I MAY be putting the car under the knife this weekend if everything happens correctly (still need to find a welder so I can build a proper mount).

Simple hand sketch of how I want to mount and plumb my cooling front end
http://www.rotarycarclub.com/rotary_...0&d=1269667364
2D cut away of an intake manifold I will probably build as soon as I qualify my design with some CFD.
http://www.rotarycarclub.com/rotary_...1&d=1269667373
My math that shows you I have too much time on my hands:
http://www.rotarycarclub.com/rotary_...2&d=1269667384
and for those that can't use their imagination here's a 3D view of part of my intake manifold design:
http://www.rotarycarclub.com/rotary_...3&d=1269667394

I like it. Picture is a little fuzzy... what is the cylinder in the pass front corner?

Welder or weldor? :suspect:

And that Math bring back memories of my AP calc class.... except that looks more like a nighmare than a daydream ;)

Scavenge pump.

I need to borrow someones mig. Shouldn't take me but a couple of hours, if that

Those formulas make me want to put my face right through my computer screen. I hope the manifold works out for you. It is good to know we have some big thinkers in our rotary community, you seem to be a very virtuoso person.

my brain just turned to mush....

Just cut out the lengths and prepped them for welding which I'll do tomorrow. I'll also post up pictures of it. I ended up using 2in shy of 6 feet of angle iron. This mount will not bend/break at all--Unless I decided to wrap my car around a tree (don't worry I knocked on wood).

As for the math it's not THAT complicated. It's more algebra than anything. Well I think I took a derivative or two, but that's it.

Also what you can't really see B is the drain petcock; it's moved off of the T junction and is underneath the car itself so I don't have to finagle myself under it to drain it without a mess. Also the lower air intake vent may become automated so that depending on conditions and speed I can tell it to take in additional air from below the intercooler. Though that might be after I am able to paint the car and what not.

The Scavenge pump is setup to be cooled by incoming air as well and the reduction in the volume accessible by the air will increase flow velocity which means additional heat transfer from the radiator to the ambient air.

I'm still trying to figure out how to mount the fan properly (I'd prefer not to use the Autozone feed through pieces they sell), it's about 14in Diameter and the radiator itself tops out at 13.25 in at the core. I think that might just be enough to ensure maximum coverage of the fan without causing issue, but I'll be attempting to make a shroud and enable the fan to function much better than it's current setup.

[cliffs]Radiator mount will be fabbed up tomorrow, radiator fitment worked out, and additional issues will be figured out for certain.[/cliffs]

For a fan mount, skip that feed through garbage. Build a shroud that bolts in, slips in with the mounting, dzus fasteners, etc and mount the fan to that.

Other than that the setup looks and sounds awesome. What are going to be the parameters for how that flap moves, directs airflow?

Honestly I'm still figuring it out. I think a few main ones are coolant temp, air temp at intercooler, and car speed.

If atemp<some number
{
If ctemp>some other number
{
If speed>some number 2
{
Lip open
}
Else
{
Lip close
}
}
Else
{
Lip close
}
}
Else
{
Lip close
}
}

That's my thinking though. Also weather went to crap doesn't look like I'll be welding today, which sucks

Another update
 

Figured I'd post up another update for everyone. The weather has detoriorated to a thunderstorm and ~40 Degrees so I wont be welding up my mount today, so instead I hit the mounts a little bit so they can look nicer but still have a fantastic function.

Here's what I started with (a rough cut that I made just to do welding in a few hours):
http://www.rotarycarclub.com/rotary_...3&d=1269808804
Mock up on radiator:
http://www.rotarycarclub.com/rotary_...4&d=1269808812

Since the weather went to crap I re-did some cuts and what not:
http://www.rotarycarclub.com/rotary_...5&d=1269808825
http://www.rotarycarclub.com/rotary_...6&d=1269808835

And the end result:
http://www.rotarycarclub.com/rotary_...7&d=1269808843

The current state
 

More of the final result:
http://www.rotarycarclub.com/rotary_...8&d=1269809006
http://www.rotarycarclub.com/rotary_...9&d=1269809015

Will post more when I finish the cross bracings.

by the way, all cuts and fitments were done by hand (Hack saw and file). I could weld this with a tig and it would look amazing!

Well, isolating a MIG to borrow for an hour or two has turned out to be harder than anticipated, but I should be able to weld it up this weekend (knock on wood). I've started modifying the radiator and hope to have it ready for TIG welding sometime next week. This includes not only the mounts that I hacked off from the original but also a brand new mounting scheme that I'm still figuring out.

I'm thinking I'll be able to just simply construct some aluminum mounts that mimic the factory mounts; my concern however is the vibration, force, and torque applied to the radiator from different locations and conditions will eventually deform the mounting holes and result in catastrophic failure of the radiator. I have become severely paranoid about that since the last radiator mount deteriorated so quickly.

Here's a rough 3D view of what I'm considering:
http://www.rotarycarclub.com/rotary_...7&d=1270255113
http://www.rotarycarclub.com/rotary_...8&d=1270255119
As it stands, I still need to pick up some bulkhead fittings. one -4 and 2 -6 AN bulkhead fittings, and then I need to start cutting and bending the hard line to the application. I'll then be taking the lines to be flared at a hydraulics shop and fitted with the nickel AN nuts I bought recently. I'll also need to figure out the NPT size fittings for the drain petcock so I can put in a t junction to fit both the hard line and the Coolant Temp Sensor.

Speaking of which, does anyone know the thread pitch and what not for the coolant temp sensor? Pretty sure it's NPT.

I'm also probably going to begin construction of the fan shroud and mounting scheme tomorrow (hopefully I'll have the steel welding done too)... Busy, busy, busy.

Finally found a welder...
 

So I finally found a welder, and I did some craptacular welds full of flux core. I also drilled out the holes for the bulkhead connectors (I didn't have a drill press or C-Clamps when I did those, so... I eyeballed it and used my feet).

Here's also the bulk head connectors that will be very useful for my uberclean cooling system.

Progress is slow...
http://i123.photobucket.com/albums/o...g/IMG00059.jpg
http://i123.photobucket.com/albums/o...g/IMG00060.jpg

Should be welded up tomorrow hopefully.

Damn T, that looks damn awesome..... I don't know why I missed the update 2 weeks ago

It's all good, no worries. I can't wait for it to be welded up and then we can get the ball rolling on the recirculation tank. I still have a few things to do... All with steel line... gahhhh.

Went to a local hydraulics shop and had them flare this out for me: Here's a Mock Up:
http://i123.photobucket.com/albums/o...g/IMG00061.jpg

Welding should be done today around 5 or so.

I are furious! I installed the mount and radiator then while I was driving home a hose slipped off an adapter and dumped all my coolant on the road in front of my apartment. Pulled it into a parking spot, turned it off (clouds of coolant all over the place), opened the hood and see the entire engine bay sprayed in coolant.

Here's what it originally looked like before the coolant spraying everywhere:
http://i123.photobucket.com/albums/o...g/IMG00062.jpg
http://i123.photobucket.com/albums/o...g/IMG00063.jpg

so the line was made by the shop or you did it and the shop flared for the B-nut? im curious cause i want to venture into some hard line stuff as its cheaper than all rubber/teflon AN's by about half even after getting the tools. and was wondering how it is to work with for bending fitting?

z

I bent, they flared. Not a bad gig honestly. I'm hoping for much more compact attachments.

I'll get pictures posted up tomorrow sometime with the new setup (fan, and mounting scheme)

http://i123.photobucket.com/albums/o...g/IMG00071.jpg
http://i123.photobucket.com/albums/o...g/IMG00072.jpg
http://i123.photobucket.com/albums/o...g/IMG00073.jpg

Made that mounting scheme for the fan in 4.5 hours just in time to go drag racing. Now i'm looking forward to constructing my own intake manifold, and getting a proper standalone in there.

Looks good man... you back in Culpeper yet? We've been having some fun days in the garages working on 8s...

Not yet. Mid may... I'll check my voice mail tomorrow to double check but I want to say I start May 17th.

:icon_tup:

Will be back in town around May 17th (will have some work to do on the car too; just found out i'm leaking from a pin-hole leak behind the water pump housing).


Well, it's finals here at VT so I've been kind of swamped with studying (have a final at 445 in structures, which should be fun), but in between studying for finals I've found some fun in doing some CFD analysis for my manifold design (off the shelf manifold parts available for purchase via your local google store search)

Here are two pictures: First flow is roughly NA, second flow is under pressure.
http://www.rotarycarclub.com/rotary_...1&d=1273516444
http://www.rotarycarclub.com/rotary_...1&d=1273516455

I figure it's time for an update. Consequently a lot of work has been done with research into the proper intake manifold design. Here are some of my results. As you'll no doubt notice, the flow characteristics have not improved, but in fact have decreased significantly from the original flow pattern. Have no fear though, I still have a few things up my sleeve to nail down the proper flow.

Design Iteration 2: Modified Plenum Chamber:
Low Velocity
http://www.rotarycarclub.com/rotary_...1&d=1274235145
High Velocity
http://www.rotarycarclub.com/rotary_...1&d=1274235136

Design Iteration 3: Modified Runner Inlet Angle:
Low Velocity
http://www.rotarycarclub.com/rotary_...1&d=1274235164
High Velocity
http://www.rotarycarclub.com/rotary_...1&d=1274235155

So I talked to a guy I work with that actually does CFD analysis for a living and he's informed me that the reason that the manifold doesn't work correctly at high speeds is because the intake flow is too fast. This means it might be much, much easier to solve my problem than I originally thought, and it will mean I have ability to add some nice fancy features.

That is some really cool shit T

Quick text update: I'm running more CFD and adjusting my design for the intake now. Talking with my only source for CFD understanding I have come to the conclusion the intake will be fairly transient with the current setup. I'm doing minor alterations to further correct the flow distribution to the runners, and should be close in the next few days. (I'm getting some flutter--not large--between the primary runners)

Here's a movie (or 2). The first video is actually the progression of the latter video (the latest design iteration). I need just a little more work to even out the flow on the number 3 and 4 runners (you'll see what I mean), but it's coming together a lot more quickly now.

http://i123.photobucket.com/albums/o...e_01_sym_a.jpg
http://i123.photobucket.com/albums/o..._Intake_01.jpg


(Side note, I'd like to host these directly on the RCC, but they're a little big for upload)

Son of a Bitch! The last little part of my manifold is starting to piss me off. So I went outside and bent some hard line for the scavenge pump I have sitting on my chest of drawers. I've got 1/2 done. The hardest line is about 1/2 done and that is the line that goes to my oil pan from the scavenge pump. It's got to go over the power steering rack, over the roll bar, under the turbo manifold, and under or around the wastegate. This is going to be quite the long line, but should prove kind of fun in the process.


Now that I think about it If I really, really, really, wanted to (which I don't since I've already got the bulkhead fittings and cut and mounted the radiator frame), I could have just mounted the scavenge pump on the frame rails some place. I didn't because I thought I'd take a piece out of TTT's book and go around my elbow to get to my ass (Nothing but love TTT).

I also should be buying the PS1k+digi dash bundle here in the next few weeks, which should be really nice. I'm getting excited. Now I just need to either decide if I want to wait on installing it until I build the intake manifold, or just install it and epoxy all my manifold lines on... oh the possibilities. lol

Suggestions/thoughts? I'm really open to what I should do timeline wise.

Here's an Update... Especially for B.
















































































http://www2.haltech.com.au/images/si...1000%20web.jpg



Suck it.

I have one of those to it's been in my car for the last year

LOL... :rofl::rofl::rofl:
Where did you get yours from? I was on the last buy though Ludwig motorsports but I havn't made any progress on my car lately :( so mine is sitting in the file cabinet should I take a pic of it for him?

I think you should... I'll print a few out and tape them to his ride next time he's around. Start hiding them EVERYWHERE, lol..

I got mine from Ludwig. I got a good deal from him so I'm happy about it.
...:squint:....

I'm on to you.

Welp, the ECU arrived today! Who wants to help me tune ;)

I've been setting up the preliminary tuning table for the car (doing it from scratch because I'm a masochist) and I have some options that I think I like. Here's some screen shots.

I still need to do a few things before I begin to install the EMS. They are (in no particular order)

1. Pay second exhaust ticket
2. Buy exhaust components (mandrel bends, mufflers, etc)
3. Put car in the shop to get the exhaust welded up properly
4. Sell the RTek 2.1, Cable, and Palm T|X
5. Sell Prosport Gauges
6. Sell S4 Dash
7. Buy Vehicle speed Sensor (the transmission type)
8. Buy Amps for EGT sensors
9. Buy Coils/Igniters for Direct fire
10. Buy Digi Dash
11. Install ECU/Components
12. Sell engine components
13. Tune
14. Enjoy redline

Another update:

Received new mufflers to quite down my exhaust noise. Should be going to the shop to get it put on sometime in the not too distant future; just need to order and get some mandrel bends.

I also have finalized the intake geometry volume for the plenum I've been designing. The results will be posted shortly.

http://i123.photobucket.com/albums/o..._05_sym_07.jpg
http://i123.photobucket.com/albums/o..._05_sym_06.jpg
http://i123.photobucket.com/albums/o..._05_sym_05.jpg
http://i123.photobucket.com/albums/o..._05_sym_04.jpg
http://i123.photobucket.com/albums/o..._05_sym_03.jpg
http://i123.photobucket.com/albums/o..._05_sym_02.jpg
http://i123.photobucket.com/albums/o..._05_sym_01.jpg

Well the time has come for the car to go into the shop for a quieter exhaust system. All my parts for it have come in and I figure I'll let a professional have to swear at the car especially because he HAS to make it look nice and can't do a job like the midlands of 'that'll do'.

My exhaust system will be composed of the Racing beat universal 3in pre-silencer, a Magnaflow 3in inlet to dual 2.5in outlet to a dual Magnaflow 2.5in inlet/outlet circular mufflers without offset to dual Magnaflow 2.5in inlet/outlet with offset oval type mufflers. For those keeping count that's 6 muffling devices. This should quiet me down a lot. Some say this is overkill, some say it reminds them of a Ferrari exhaust, all I know is that if this doesn't quiet down the car I'm going to have to put in a 'buttplug' (into the exhaust system. Get your mind out of the gutter!).