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