Joff and MrsJoff's Chaste White BorgWarner FD build

NoDOHC · 10-13-2010, 11:29 PM

Wow! That intake boot is a work of art! I like how the fabric shows through the clear resin. I am curious why the wrinkle partway down, does that go around something?

The car looks amazing. Nice work!

joff · 10-14-2010, 10:33 AM

Quote:

Originally Posted by NoDOHC

Wow! That intake boot is a work of art! I like how the fabric shows through the clear resin. I am curious why the wrinkle partway down, does that go around something?

The car looks amazing. Nice work!

Thank you!

That wrinkle is there to form fit around the radiator and the reinforcement bar that slightly curves inward where the hood latch is. The pic above of it in the engine bay is slightly wrong -- its supposed to slide a little more (1") forward and fit flush against that bar.

RCCAZ 1 · 10-16-2010, 09:57 AM

Looking good guys. I have a special part coming for my car that I need to make you aware of. Will call you sometime today (Sat) so we can discuss some more. Jesse... looking incredible bro. I take it that this is the new higher temp epoxy on the duct, correct??

joff · 10-17-2010, 01:10 AM

Quote:

Originally Posted by RCCAZ 1

Looking good guys. I have a special part coming for my car that I need to make you aware of. Will call you sometime today (Sat) so we can discuss some more. Jesse... looking incredible bro. I take it that this is the new higher temp epoxy on the duct, correct??

Yep -- I took some samples and did an experiment in the temp chamber I have at work for testing electronic circuit boards. This new resin (Silmar 249) should hold up far better to engine bay temperatures in Arizona. I should have taken a picture of the Kleer Koat epoxy sample at 80C -- it was about as flexible as a slice of cheese. Its too bad, that epoxy was by far the easiest to work with.

MrsJoff · 10-22-2010, 03:53 PM

Some pictures of Jesses' next project

With a lot of resin and fiberglass that becomes this

Again, with a lot of resin and more fiberglass that becomes this

If it is not obvious, this new project is a water/meth reservoir in the spare tire well.

joff · 12-27-2010, 06:29 PM

I stuffed a wad of steel wool down the EGR passages and JBwelded them shut. I also did the other side too.

I ported my extension manifold with a hacksaw and dremel. I removed the center support where the butterflies used to be then knife-edged and smoothed the exposed primary/secondary walls.

Now theres a better chance of taking advantage of the bigger throttle body:

joff · 01-01-2011, 08:14 PM

I used the OEM intake gasket to port match the LIM to UIM, and the gizzmo phenolic gasket to port match the LIM. It wasn't a lot of material but it sure did take awhile with the dremel.

Now that its done, I'm not sure if this was a good idea or not, as a local rotary expert told me that while it will help top end power by a few hp, it may create excessive intake reversion and low speed cruise backfiring/sputtering. Anybody else have any experience with this?

I'm hoping the effect is minimal on my mostly stock ports as I anticipate a bit of a driveability loss already by replacing the stock throttle body and loosing the way it opened up the primary butterfly first.

Xcessive LIM top (to stock UIM):

Xcessive LIM bottom:

stock UIM (to LIM):

10-13-2010, 11:29 PM	#1
NoDOHC The quest for more torque Join Date: Sep 2008 Location: Sheboygan, Wisconsin Posts: 855 Rep Power: 17	Wow! That intake boot is a work of art! I like how the fabric shows through the clear resin. I am curious why the wrinkle partway down, does that go around something? The car looks amazing. Nice work! __________________ 1986 GXL ('87 4-port NA - Haltech E8, LS2 Coils. Defined Autoworks Headers, Dual 2.5" Exhaust (Dual Superflow, dBX mufflers) 1991 Coupe (KYB AGX Shocks, Eibach lowering springs, RB exhaust, Stock and Automatic)

10-16-2010, 09:57 AM	#3
RCCAZ 1 Rotary Fanatic Join Date: Mar 2008 Location: Phoenix, AZ Posts: 288 Rep Power: 18	Looking good guys. I have a special part coming for my car that I need to make you aware of. Will call you sometime today (Sat) so we can discuss some more. Jesse... looking incredible bro. I take it that this is the new higher temp epoxy on the duct, correct??

10-22-2010, 03:53 PM	#5
MrsJoff Rotary Fan in Training Join Date: Sep 2008 Location: NE Mesa, AZ Posts: 46 Rep Power: 0	Some pictures of Jesses' next project With a lot of resin and fiberglass that becomes this Again, with a lot of resin and more fiberglass that becomes this If it is not obvious, this new project is a water/meth reservoir in the spare tire well.

12-27-2010, 06:29 PM	#6
joff Rotary Fanatic Join Date: Dec 2008 Location: Mesa, Arizona Posts: 114 Rep Power: 17	I stuffed a wad of steel wool down the EGR passages and JBwelded them shut. I also did the other side too. I ported my extension manifold with a hacksaw and dremel. I removed the center support where the butterflies used to be then knife-edged and smoothed the exposed primary/secondary walls. Now theres a better chance of taking advantage of the bigger throttle body:

01-01-2011, 08:14 PM	#7
joff Rotary Fanatic Join Date: Dec 2008 Location: Mesa, Arizona Posts: 114 Rep Power: 17	I used the OEM intake gasket to port match the LIM to UIM, and the gizzmo phenolic gasket to port match the LIM. It wasn't a lot of material but it sure did take awhile with the dremel. Now that its done, I'm not sure if this was a good idea or not, as a local rotary expert told me that while it will help top end power by a few hp, it may create excessive intake reversion and low speed cruise backfiring/sputtering. Anybody else have any experience with this? I'm hoping the effect is minimal on my mostly stock ports as I anticipate a bit of a driveability loss already by replacing the stock throttle body and loosing the way it opened up the primary butterfly first. Xcessive LIM top (to stock UIM): Xcessive LIM bottom: stock UIM (to LIM):