BUILD-OFF CHALLENGE: Tygaboy's '75 LS3, It seemed a good idea at the time... Options

[Shivers]

For whatever reason, as I was moving the doors, I noticed the shape and thought, "I wonder if I could use that as the center section of a rear valance?"
It'll take some work, but I think I can. Sort of diffuser-like and a pretty neat shape.
I'd love to be able to say I used part of a '59 Metro on my build. (IMG:style_emoticons/default/aktion035.gif)
We'll see how this goes.

I like it (IMG:style_emoticons/default/smile.gif)

[Cairo94507]

I like where that is headed. (IMG:style_emoticons/default/beerchug.gif)

[burton73]

The second I saw the metal from the Metro doors I knew what it was. I had a buddy that had a metro way back. Great idea for the rear valance. Dual out flared valance it's going to be nice. You know the thing is, you do your best to design an exhaust and until it cycles through high heat and cools a number of times you are not 100% sure what it is going to do.

@technicalninja Rick had men mentioned
“I'd add some type of expansion connection to both sides before the X section.

Might be as simple as slip tubes and springs or true flex sections on v-bands.

I think the temperature swings that the system will go through will over stress that x section and it will fail without some type of stress relief.”


--- I had thought it may need some kind of Bellows because I remember what my 74 turbo 2.0 did after running it around very hard and the exhaust was glowing red and would bend a bit.I did have bellows on its SS custom system. ---

I guess if it has a problem in road testing it you will just rework it.

Anyway, your ideas as a designer and fabricator are fantastic and your work is as good as anything I have ever seen.

Best Bob B

[tygaboy]

A quick errand this morning with everything done, including tips trimmed to length. I'd swear it's quieter, too.

[Cairo94507]

Can we see a full-on side shot please? To my eye (and it could be the angle) they look a tiny bit long. (IMG:style_emoticons/default/beerchug.gif)

[tygaboy]

Can we see a full-on side shot please? To my eye (and it could be the angle) they look a tiny bit long. (IMG:style_emoticons/default/beerchug.gif)

@Cairo94507 Michael - These are the same length as the dual asymmetric I just replaced. I'm going to live with them a while. Easy enough to shorten them if I decide that's what needs to happen.

[Cairo94507]

Hi Chris- Now that I see them from the side they are fine. Sorry, they looked longer in the other angles.
Cheers,
Michael (IMG:style_emoticons/default/beerchug.gif)

[tygaboy]

Back on the intake. I fabbed a test piece to verify the plenum base plate spacing measurements. Lots of stuff to work out but it's a start.
Remember, whatever gets build, the goal is a clear top plate so you can see the stacks. Fingers crossed this actually works!

[tygaboy]

I decided to make a heat shield for the new exhaust. I was going to try and make it from aluminum but figured it'd take quite a while, I'd screw up a bunch of material, etc. So I opted to do one in carbon fiber.
First I need a mold and figured why not use it as an opportunity to learn a new skill.
So I did a bit of research and ended up with this:
- place a suitable sheet of ABS in a 225 degree oven until it "goes soft"
- drape it over the shape you want to copy
- press, weight, form and hold it in place until it cools enough to hold the shape

I was a little hesitant with the heat, what with it being my first time, and the first go didn't work out - the ABS wasn't soft enough to form a couple of the tighter areas.
The cool (!) thing is I just popped it back in the oven (don't tell my wife), bumped the heat and let it bake until I could easily fold up a corner.

Then it was: pull it out, drape it on the exhaust and quickly form it as best I could. I used a bodywork sand bag to weigh it down while I worked downward force everywhere, as best I could. Once it was clear it was no longer formable, I removed the sand bag. Here's what it looked like at that point:

[tygaboy]

Lift it off and BAM! One exhaust heat shield mold.

Pay no attention to the shape around the edges, the final part will be trimmed to look nice, be symmetrical, etc. Next, it's on to some carbon fiber layup.

It was a fun afternoon. I love adding to my skills tool box.

[cassmcentee]

(IMG:style_emoticons/default/beerchug.gif)

[East coaster]

Very cool…….that will make a perfect mold for your carbon layup. I’m not sure you’ll even need PVA with an ABS form.

[Chris914n6]

now do it again with the shiny side up (IMG:style_emoticons/default/biggrin.gif)







If it hasn't occurred why yet sleep on it...

[tygaboy]

now do it again with the shiny side up (IMG:style_emoticons/default/biggrin.gif)







If it hasn't occurred why yet sleep on it...

@Chris914n6 - Close but no cigar for you. (IMG:style_emoticons/default/happy11.gif)
The heat shield goes between the exhaust and the trans. The mold was formed on the underside of the exhaust, with the shiny side of the mold face up, since that'll end up being the "outside" of the part that shows - if you were to see it when it's attached. The inside of the final part, the side that faces up (the rough side of the part that I suspect you think I want to show) will be covered with heat reflective foil. (IMG:style_emoticons/default/shades.gif)

[Chris914n6]

now do it again with the shiny side up (IMG:style_emoticons/default/biggrin.gif)







If it hasn't occurred why yet sleep on it...

@Chris914n6 - Close but no cigar for you. (IMG:style_emoticons/default/happy11.gif)
The heat shield goes between the exhaust and the trans. The mold was formed on the underside of the exhaust, with the shiny side of the mold face up, since that'll end up being the "outside" of the part that shows - if you were to see it when it's attached. The inside of the final part, the side that faces up (the rough side of the part that I suspect you think I want to show) will be covered with heat reflective foil. (IMG:style_emoticons/default/shades.gif)

Cool with me I hate cigars (IMG:style_emoticons/default/icon8.gif)

Now that you've slept on it did it (IMG:style_emoticons/default/slap.gif) yet?

[mgp4591]

This is what happens when you leave the door unlocked...you never know who you'll see at the Red Barn!

[tygaboy]

Early arrival at yesterday's EASY gathering.

[DennisV]

Lift it off and BAM! One exhaust heat shield mold.

(IMG:style_emoticons/default/smilie_pokal.gif) Nice! Did you just buy a sheet of ABS from Tap Plastic?

Next time, I expect you to add vacuum form to your bag of tricks. You're half way there. (IMG:style_emoticons/default/popcorn[1].gif)

[tygaboy]

It's been a minute since I posted. Some personal stuff happening on the home front that's required my attention. It's mostly settled down so back into the Red Barn I go.

I'm adding an oil cooler because why not? The first step is mounting the thermostat. A happy accident is that the shape of my rockers allows this to fit underneath, even when mounted on rubber isolators. The thermostat is from Improved Racing and it's a tidy little package.
Now to make lines back to the engine and work out the cooler side of things. I may just run a loop of hose until I come up with something that appeals to me.

[tygaboy]

New exhaust back from the getting Cerakoted. I'm happy with how it turned out. I'm foregoing the heat shield for now as I'm not happy with the ABS mold but I'll be giving it another go in the future.