Joff and MrsJoff's Chaste White BorgWarner FD build

[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

[RCCAZ 1]

Looking awesome Jesse. Nice work. Where did you get that turbo blanket? Really fits nicely!! Keep it coming and let me know if you need help. I'm off now until the new year!

[joff]

Thanks for the heads up guys -- a while ago I did a little research on this and did see a thread somewhere where some of the white plastic phenolic gaskets had warped.

The gasket I have is from gizzmo and is definitely from a different material. I'd guess its something like the FR44 material we use for manufacturing circuit boards.



Is this the EGR port you were talking about?


It seems to cover it -- maybe by not much margin. I'll probably see about plugging that EGR hole with some aluminum or JBweld.



The turbo blanket I think I got from ebay. Its pretty thin actually, but that works for me because I'm a little worried about too much heat in the turbo. I painted it with the same 1500degF silicone sealant paint I painted the header wrap with.

Thanks Tim, I'd take you up on some help this week if it weren't for the fact we'll be in Tucson visiting family.

[hades]

Originally Posted by joff

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

Can you give more info on the on-line fab company you used? I model parts in Pro/E all day long. The hard part is finding a fab shop that won't rape you to make the part.

Thanks,

[hades]

CrispyRX7 port matched all of his manifolds with good results. I believe he made 422 @ 15 psi on a 35R T3.

http://www.reganrotaryracing.com/fdenginebuild.htm

http://www.reganrotaryracing.com/fde...doverview4.htm

[joff]

Originally Posted by hades

Can you give more info on the on-line fab company you used? I model parts in Pro/E all day long. The hard part is finding a fab shop that won't rape you to make the part.

Thanks,

I use emachineshop.com. You have to use their free CAD tool which isn't nearly as sophisticated as Pro/E or Solidworks, but you order straight from the software and it quotes your design in realtime which is convenient.

Its not bad $$ if you can stick to simple sheet aluminum cuts and bends. Trying to do anything that needs to be 3d machined it seems overly expensive for one-offs with emachineshop though they can do it.

Another site that can do simple metal cutting is ponoko.com. They can't bend but you can hand bend if you use the laser cut to remove slits from the bend lines. Ponoko can also do 3d printing in stainless steel or ABS.

Originally Posted by hades

CrispyRX7 port matched all of his manifolds with good results. I believe he made 422 @ 15 psi on a 35R T3.

FWIW, I actually PM'ed him to ask him if he had any obnoxious cruise/low load driveability issues and he said he had none whatsoever. I guess I'll see.

Cleaning all the metal shavings and sandblasting material out of that UIM was a real pain. The small amount of carbon buildup from the PCV/purge solenoid acted somewhat as an adhesive for all the sand/metal shavings and made them resistant to being blown out. I was pulling shop towels through the passages with wires for quite awhile before wising up and blasting the entire insides with brake cleaner to get rid of the gunk.

[speedjunkie]

Yep, that is the exact same gasket I have with the exact same specs, not completely covering the exact same EGR port LOL. I guess if you cover it with JB Weld or something that would work too. Good luck with all that. Just wanted to give you a heads up so you didn't get it together and then try to figure out where the leak was coming from LOL.

Mine looked the same btw. It looked like it was covering, but air still came out of there.

[Prodigy]

That last photo you can see a tiny little bit of the EGR port sticking out... I can see why that would warp and let create a leak....

interesting though that they make them out the same, or similar material as circuit boards...


J.

[speedjunkie]

^I don't think these are the ones that warp, I honestly think these might have a good chance of standing up to the heat. That little bit of the EGR port is enough to leak enough air to make it sound like a motorcycle. So it's already bad just the way it is, it doesn't take warping to make it sound like crap haha. And the ones the other guys on 7club had were made by a different company I believe. So far no one that has had a Gizzmo one (that I know of) has had it warp. It's just not cut right.

[Easy_E1]

Looks like you've been busy. Can't wait to see it on the road Jesse.