Joff and MrsJoff's Chaste White BorgWarner FD build

[MrsJoff]

This post is not about the FD, sorry. But, since we are in Las Vegas, it is about SEMA. Just having to brag a little bit. While walking around we ran into Tanner Foust and I got a sig and pic with him. I LOVE Tanner!!!



I don't know who the little bald guy is, he kind of slipped into the picture. He is some drifter guy that competes with Tanner.

And for all you Petrol Heads, we were invited to an exclusive screening of the History Channels U.S. version of Top Gear.



While Jesse and I were sitting there waiting for the show to begin we mentioned how we would never accept the new hosts since they would not be Jeremy, Richard or Captain Slow. Much to our surprise and excitement, one of the new hosts is TANNER FOUST!!!! Did I mention how much I LOVE Tanner?!!!?? They did not change a thing about the show. The great cinematography is the same, the same type of challenges and commentary while driving in the cars. I think they did a great job. And Tanner Foust is in it They went with the History Channel so they can give honest opinions of the cars, without bothering whether it hurts the car manufacturer. The show starts Nov 21st at 10pm. Set your Tivo's now!!

We also got video of Ken Block drifting in the parking lot. He was giving ride alongs in his bad ass little 650hp Ford Fiesta. That would be a blast, as long as they had a barf bucket in there. We will post all the pics and videos in the regional section once we get back home.

[speedjunkie]

The "little bald guy" is Stephen Papadakis LOL!! AFAIK he stared out drag racing Civics back in the day and now he's moved on to drifting, an S2000 I believe.

That's cool you got to meet those guys though. I wish we could have made SEMA again this year

I love the water/meth tank btw, my roommate was going to have one made but the company quoted him about $8k, YIKES!!

[joff]

The fiberglass water/meth reservoir is done. It holds 3.9 gallons and locks in perfectly to the contours of the spare tire well. I'm going to use the stock rear washer fluid reservoir with a hidden hose to the spare-tire reservoir too for convenient fillup and slightly increased capacity. The rear pickup and internal baffling should keep things safe when accelerating or cornering.

[NoDOHC]

That is cool, did you use a black resin or paint that tank?

The baffles are a really good idea, not only do they constrain the fuel, they add strength and support for the rear hatch area.

Keep up the good work

[joff]

Originally Posted by NoDOHC

That is cool, did you use a black resin or paint that tank?

The baffles are a really good idea, not only do they constrain the fuel, they add strength and support for the rear hatch area.

Keep up the good work

No, I used vinylester resin which dries a semi-translucent amber. The black is a truck bed liner spraycan.

[muibubbles]

awesome man. do u have abetter picture of how the baffles work? i love this idea because the spare tire well is such a waste of space... great idea!

[joff]

Originally Posted by muibubbles

awesome man. do u have abetter picture of how the baffles work? i love this idea because the spare tire well is such a waste of space... great idea!

There are four "chambers" as shown below.

Under straight line acceleration, the fluid will collect toward the rear and the pickup is in the rear, so no problem there.

Under lateral/cornering g-forces, the fluid on the sides must flow through the rear pickup chamber to get from one side to the other. The holes between the chambers are not big, so flow rate from one side of the reservoir to the other takes a long time.

[Prodigy]

Have you considered creating something so it makes the passageways one way? little rubber flap or something to discourage the fluid from exiting the pickup point....?


either way, looks great...


I'm currently considering removed my spare tire and getting a size appropriate battery, and mount it in the wheel well, As I have rear seats, and despise having the battery sitting out in open, maybe get a Braille battery that can be mounted sideways....

Looks great, waiting for more updates...


J.

[joff]

Originally Posted by Prodigy

Have you considered creating something so it makes the passageways one way? little rubber flap or something to discourage the fluid from exiting the pickup point....?

one way check valves sound neat, but I think I've overengineered this thing enough. :-) I need to move on and finish the rest of this.

One of the reasons I went with such a large reservoir was partially to compensate a small intercooler by spraying more water/meth. This is now moot as I've had to abandon that PFS intercooler because I didn't like how I was going to have run the ductwork. So I decided to just do a vmount. Rotary-works sells a good starting point for a semi roll-your-own vmount.



Nice thing about this setup is I have a lot of room to run a cold/ram air intake into the turbo-- I had to change and make some of my own brackets because the stock brackets center the intercooler (I shifted it all the way to the drivers side), but no welding which is good. The radiator and intercooler already have some M8x1.25 screw bosses welded on to make mount tweaking pretty easy.



The radiator did not have to be modified and is designed for this mounting configuration and has a nice clean looking bottom endtank:



One more pic: I header-wrapped my exhaust manifold with some lava-rock type header wrap that looks like carbon fiber and then painted it with some silicone-based header wrap paint. I also drilled & re-tapped the turbo flange to fit the expensive OEM inconel studs used on the stock twins.

[muibubbles]

awesomeness. im assuming the water/meth tank is 100% fiberglassed so there is no way of reopening it?

thanks for the explanation, always wondered how the baffle system worked and it makes so much sense lol

[RCCAZ 1]

Hah.... I also detect a 99 spec nose? Nice. Let me know if you need me to stop over and assist with ducting. I really enjoy doing that part and definitely owe you some "labor"

[dregg100]

im gonna bet burnout on that front bumper...looking good guys, this will be one clean car when its finished.

[joff]

Originally Posted by dregg100

im gonna bet burnout on that front bumper...looking good guys, this will be one clean car when its finished.

Thanks! And, yep, its a burnout front bumper.

I tried to use this formable inferno heat shield thing on the xcessive intake manifold and got it perfectly formed and even fabbed some riveted brackets to hold it perfectly on the LIM but when I put it back on the car, I didn't have enough clearance between the wastegate & LIM. So-- I had to scrap that unfortunately. I was quite proud of how simply and securely I had it mounted too.

So instead, I bought some of this thin stick-on heatshield from Jegs comprised of a high temp adhesive, a layer of fiberglass, then aluminum foil. First I formed it tightly around the curves of the LIM -- making sure to shield all the way to the bottom edge. Then I added a second layer towards the top where I had more clearance and where the downpipe will run. The second layer I wrapped straigt & tight and left a bit of an air-gap instead of following the curves.

Its ugly now, but hopefully pretty functional. I also have one of these phenolic spacer gaskets that act as a barrier for conducted heat transfer from the block to the manifold. Not sure how well it will be as a gasket since its pretty hard and inflexible, but thats what RTV is for anyway. There definitely seems to be a lot of surface area on the LIM for heat conduction from the block that should now be blocked.



Also, I designed in CAD and mocked up my airbox for the vmount. I think it will end up working pretty well. I tried to make it match the end tanks of the intercooler both for aesthetics and because I want it to be a tight fit & seal. I'll be sending this design to an online machineshop to be cut and formed out of .062" aluminum

[Prodigy]

Looking great Jeff... the build seems to be coming along nicely...

Originally Posted by joff

Its ugly now, but hopefully pretty functional. I also have one of these phenolic spacer gaskets that act as a barrier for conducted heat transfer from the block to the manifold.

I was reading a thread on 7club http://www.rx7club.com/showthread.php?t=803695 and it was talking about some guys having troubles with the LIM to Keg gaskets dis forming and melting, while the UIM to LIM worked fine... while others had not trouble at all...

not sure if you have the same brand or such, but figured I would bring it to your attention..

Man you do good work, waiting to see how that intake looks once done...


J.

[speedjunkie]

EDIT: ^Yep, I wasn't one of the guys with a deformed one but mine didn't work for me anyway. I think mine was made of something different than the ones that were deforming, I think mine is sturdier than that. If only it had been cut right.

Originally Posted by joff

Thanks! And, yep, its a burnout front bumper.

I tried to use this formable inferno heat shield thing on the xcessive intake manifold and got it perfectly formed and even fabbed some riveted brackets to hold it perfectly on the LIM but when I put it back on the car, I didn't have enough clearance between the wastegate & LIM. So-- I had to scrap that unfortunately. I was quite proud of how simply and securely I had it mounted too.

So instead, I bought some of this thin stick-on heatshield from Jegs comprised of a high temp adhesive, a layer of fiberglass, then aluminum foil. First I formed it tightly around the curves of the LIM -- making sure to shield all the way to the bottom edge. Then I added a second layer towards the top where I had more clearance and where the downpipe will run. The second layer I wrapped straigt & tight and left a bit of an air-gap instead of following the curves.

Its ugly now, but hopefully pretty functional. I also have one of these phenolic spacer gaskets that act as a barrier for conducted heat transfer from the block to the manifold. Not sure how well it will be as a gasket since its pretty hard and inflexible, but thats what RTV is for anyway. There definitely seems to be a lot of surface area on the LIM for heat conduction from the block that should now be blocked.

Your LIM wrapping job looks MUCH better than mine HAHA. I got the same kind of stuff to cover mine, I don't think I have pics on my computer though. It would just make you laugh anyway haha.

Also, I'd check that gasket first if I were you. Is it from Gizzmo or somewhere else? I got one from Gizzmo and it didn't match up exactly with the OEM gasket and ended up not completely covering the EGR port, which gave me an air leak. Before I figured that out I also tried red RTV, so that doesn't work either LOL. Just put the phenolic gasket on top of the OEM one and see if it's EXACTLY like the OEM one (you can see the difference of mine in the pics). I ended up getting some spacers made with waterjet that I'm going to use to space my fuel rails apart instead.

Here is the thread about the gasket...
http://rotarycarclub.com/rotary_foru...ad.php?t=12949