So cold and hot stuff arrived today.
Still got some more stuff to arrive for the intake, following comments on the design I'll be looking for a way to keep the barrel as far from the heat as possible.








Shortened the bolts that should attach the waste gate.

did some clear coating today - there are probably lots of drips but I'm happy (so far) with the results. Managed to setup and pack down in under and hour so all good :-)
Plus this means I can move the welder back into the shed for the next stage as I don't need the compressor in there now..

My nice shiny muffler arrived today- it's very shiny but rather heavy! Way more so than my cobra.




I'm using the old exhaust to try band figure out roughly where the exhaust tip will need to come out- coupled with the rear under tray.

I have a rough idea I think.


Moved the compressor out of the shed and put the welder in there... waiting for stainless filler rods to arrive, as I only have mild steel ones that I've been practicing on (badly).

So now (in theory) I can start chopping up the exhaust material I have and making something of it!

@jvanzyl

I do admire your enthusiasm John, but your choice of workshop footwear much less so!

Quote from: Joesson on September  7, 2023, 20:12@jvanzyl

I do admire your enthusiasm John, but your choice of workshop footwear much less so!

It was 35C in the workshop!! I was literally sweating just standing there

90 degree bend arrived today    which means I could finish the layout of the charge cooling system!



I've uploaded a video of it installed:
https://youtu.be/SivyNo6MHTU?si=tGfrTjlYRtXR6sUR

I won't attempt heat shield a la @MannyUK  until I have the exhaust in place.

Started putting the rear suspension back on so I don't lose it somewhere..





Out of interest, how do you stop the "stud" from spinning here? I can't see any flat grooves at its base to gain purchase on.. and I don't remember this being an issue last time..

Shouldnt you have done something with the rust on the body before you start putting the arms back on?

The access would be a bit easier.

Quote from: jvanzyl on September 11, 2023, 13:26Started putting the rear suspension back on so I don't lose it somewhere..

Out of interest, how do you stop the "stud" from spinning here? I can't see any flat grooves at its base to gain purchase on.. and I don't remember this being an issue last time..

[/quote]

Knock the taper into the socket with a heavy soft faced hammer.

Quote from: Topdownman on September 11, 2023, 14:07Shouldnt you have done something with the rust on the body before you start putting the arms back on?

The access would be a bit easier.

I've ordered one of those kanjo subframes, so it's all coming off again for that. I honestly did consider doing it now- but given my rate of work, it's yet another thing to deal with prior to doing the turbo. So I'm going to deal with that stuff next year/when subframe arrives.

Quote from: Carolyn on September 11, 2023, 14:20Knock the taper into the socket with a heavy soft faced hammer.

Excellent! Thank you!

Had to resort to this but it worked! Thank you.


All suspension arms back on- will likely come off again before the end- torquing up will take place with all wheels on the floor whenever that is.

Have marked up the first u bend for "shortening", the slight problem I face is that the exhaust will need to turn 25 degrees towards the rear of the car quickly after exiting the turbo as it aims straight for the gearbox.

I had initially thought I'd go immediately to the flexi connection then onto the hard pipes, but I'm guessing doing a slash cut in order to avoid the gearbox isn't going to work.

I sort of need to make a slight kink to clear it..

Started back on the tig welding practice... then had to stop due to time and getting the tungsten tip totally covered... going to need a lot more practice.

Have ordered 2x 45 mandrel bends. The theory is that I can create a kind of "S bend" on the way to the full 180 I bend. This is all dependent upon my ability to weld. Today's practice was marginally better than yesterday's.. suffice to say I still suck.

I think I saw the "pool" forming properly today- but keeping it going, and making progression along the path/ not getting stuck etc is still eluding me.

Quote from: jvanzyl on September 13, 2023, 13:14Have ordered 2x 45 mandrel bends. The theory is that I can create a kind of "S bend" on the way to the full 180 I bend. This is all dependent upon my ability to weld. Today's practice was marginally better than yesterday's.. suffice to say I still suck.

I think I saw the "pool" forming properly today- but keeping it going, and making progression along the path/ not getting stuck etc is still eluding me.

Just tack it together and take it to a pro tig welder.  It takes years to be good at Tigging.

Quote from: Carolyn on September 13, 2023, 15:44Just tack it together and take it to a pro tig welder.  It takes years to be good at Tigging.

this is the plan if it I'm unable to up my game... watched a quick video that had some decent tips and then had another go.. got better results. Still need a bit more temp/amps and need to get consistent with my distance as I have a tendency to pull away too much.

Slow progress at the moment, however I'm still enjoying it!

Tacked the v-band onto the flexi joint, this may or may not be the right decision in terms of placement as the next stage was to do the 180 u bend. I slightly adjusted the angle coming out of the flex in order to steer around the transmission. However as you can see at the current angle it only allows for about an inch or less of clearance of the rubber boot..







I don't think this is ideal as the exhaust will cook the boot in no time, so I've now undone my overly enthusiastic tacking (lots of grinding later and reduction in amperage) and plan to go flex -> 45 degree angle ->45 the other direction and then into the u-bend etc.. wish me luck!

Tacked the first part of the 45 bend on and then had the low battery light on the welding mask flick on so figured better to change sooner than later.. and whoa it's a fat CR2450!

Gameplay to resume tomorrow pending delivery of fat battery..

So! Progress of sorts!...

Tacked my 45 degree bend onto the flexi,


And I've decided that although I now have more than an inch from that little rubber boot, I'm going to have to grind down and clearance these little nubs on the gear box.. please someone say if that's a bad idea!



Measured and cut the next part, have left a lot of meat on there in case I need to alter it further (which it turns out I do)


Then fitted it



Then cut and fit the u bend.



Offered up the cat, and I'm pleased I cut the angle correctly as it's now horizontal and in line with the cross member. However it's all taken up too much space and not leaving enough room for the muffler.


So I'm going to chop the straight section here down further which will bring the whole setup closer to the engine and allow more room for the muffler. 



Next steps will also be to figure out the exhaust brackets, I'd like to be able to reuse the oem points, but we'll see.

So I chopped out the straight section... the observant among you will see that I'm literally back where I started in terms of curvature and shape!    Oh well




Then retacked it together and added the Cat. Have mounted it here to figure out next steps, which really must be the exhaust hangers... just not sure where to put them...

Ended up chopping too much off the straight section and then had to re add it back... this may end up in me just buying two new 180 bends and making the cuts in the right place this time!

Anyway- behold! I made something! (Almost). Will look to put the next set of v-bands right before the muffler.

John, I think your mounting straps are going to melt as soon as you fire it up.....

Quote from: Topdownman on October  5, 2023, 17:11John, I think your mounting straps are going to melt as soon as you fire it up.....

Never! 

I'm not 100% set on the position of the muffler... might be too high and melt the bumper.

So I've working on the vbands and managed to do my first exhaust hanger!





However I some how managed to get the angle wrong on the vbands.. so either I'm ok with the exhaust being a bit wonky or I chop it and redo it so it sits straight.




One of the muffler hangers is looking to possibly be about here




I suspect that this is going to get too hot though and melt. I'm really trying to reuse the oem mounting points, might have to rethink this though.

Stuff it- don't care about the angle.

However I do care about melting my exhaust hangers. Have elected to not use the top left stock hanger mount and create 2x of my own. So muffler will stay where it is, but the mounts will come off the frame.

Managed a couple of hours tonight.

Look @Topdownman no straps!

I shall no longer use the word "bodged" I shall use "horrific" as in look what I horrificked together. This is a good description.

I'm proud of you!