21/11/05 Chargecooler layout considerations
Finally managed to get some cash together to carry on with the chargecoolers. Ordered 3off 100mm x 255mm 4 row water cores from Pace Products.
Ive decided to put the chargecooler in the engine bay rather than the inner wing,Mainly because I didn't like the look of all the charge piping going everywhere. As ever, first task was to take some digital photo's and sketch out some ideas.
Option 1: Three cores out front:
Option 2 and 3: One core either side or front and back:
Now children, when your'e in skool wondering what's the point of trigonometry and that will never be any use to you...think again; This little creation took me ages to make because I couldn't work out how draw the angled bit on a flat piece of paper which would fold into the correct shape without any gaps.
The final design choice is the three in a row design, as its the most effective.
First step is to fabricate the end tanks. These are made from a single piece and
then divided up to form the compartments later.(Which doesn't seal very well, don’t
copy this idea -
Original plan was to butt-
Despite cleaning the ally flanges up, I still suffered from dirty welds -
Once all the holes were patched, you cut a slot down the tank and weld in a divider to form the water compartments. Tried it out on the bench with a 3KW fan and my pump unit.
30/12/05 Charge tank fabrication
Cut the hole out with a Jig saw, was only supposed to tack weld it inside -
Tricky bit of welding the 3mm plate to the 6mm top-
Scored a cheap motorbike radiator to use as a pre-
Yes, the bonnet does close!
Another weekend of welding gets most of the cooler completed. Can now start on the connecting pipes.
Charge pipes done. Although not seen in this photo, the other side is very short which made getting the tig welder in very difficult.
When I originally fitted the dowel rods that prevent the charge tank from ballooning,
I didn't clamp the assembly together -
Drill press used with a centre to ensure the tap goes in straight. I used a 3/8 BSP which is fairly close to the 3/8 NPTF for the air temp sensor.
All welding completed. Pressure tested the charge side, no leaks at-