Plastic Fantastic tew

[SuperBuickGuy]

started the day laying out another airbox....

finally came to this conclusion

the problem was, as is the case here, hood clearance

first I built an air cleaner retainer

envisioning tape

then a cap

then a bit of checking

then finally a weld together... it will be black, but I'm still down 2 blocks - so not painting until done

then started working on these

I've got short strand filler and I'll beeswax the body so it doesn't stick. I need these to bolt on.... that said, I will 3d scan them so I can print out new ones if needed

[SuperBuickGuy]

didn't spend time on this tonight but got some trim... need to trim it to make it work, but what's new?

[SuperBuickGuy]

how bout a strip or three of foam tape ( the sticky on one side kind )
that way it will brace the hood and it wont rattle....
at least if your motor mounts hold up. if the left lets go, rattles
will be eliminated completely as the engine bursts thru the hood
like the 'welderup' 55 chevy....

maybe I can convince Anthony to do that with his truck? I am an evil, evil influence.....

[fatguyzinc]

and I still have a problem with it up against the hood... though I'm not sure I care - it's maybe 1/4" tall - given the hood flexes at high speed, a brace would actually kind of help. it doesn't rattle... but we'll see.... I also may decide to completely remake it
]

how bout a strip or three of foam tape ( the sticky on one side kind )
that way it will brace the hood and it wont rattle....
at least if your motor mounts hold up. if the left lets go, rattles
will be eliminated completely as the engine bursts thru the hood
like the 'welderup' 55 chevy....

[SuperBuickGuy]

tonight was more of a void-the-warranty night then get anything done
a month from order to delivery.... which isn't bad, last year it was 6 months estimate

they also wrapped it very well

what I get? spoiler alert, it's a spoiler

and, of course, it doesn't fit

I know, I know, what kind of fly-by-night supplier doesn't make a non-factory spoiler for a C3 Corvette with 2" flares?
thankfully, I know how to use these tools

cut it apart, widen it 4"

then figure out how to fill in the holes.... of course the curve isn't right either (which, tip for those following along, at SEMA, I spent some time understanding what the big builders do to make spoilers work.... simply put they cut the lower splash guard then rotate it to a more vertical orientation)... which is what I'll do next time

then time to cut up the airbox again and make it fit better

and I still have a problem with it up against the hood... though I'm not sure I care - it's maybe 1/4" tall - given the hood flexes at high speed, a brace would actually kind of help. it doesn't rattle... but we'll see.... I also may decide to completely remake it
the transition from square to round isn't something I love - I dunno, I have a couple days before I can get back to this so between now and then, I'll think on it

[SuperBuickGuy]

onward back to metal manipulation

key here is that this is hour 8 but only hour 2 of actual work.

you shall bend to my will

the hardest part was, of course, clamping. With aluminum, adding filler is almost mandatory - so you need at least 3 hands

and unlike steel, there is little memory to the metal, so you can distort it then tap it right back into shape

but lord knows there were some ugly welds to get it to stick together

first fit

then I needed to work on the pan portion and add flanges

and finish the bottom side

it seems it worked

well, would you look at that

but still, there is quite a bit more work, need to go square to round though I've found that preliminary-finish can help the process

all that work and I'm painting it black..

[SuperBuickGuy]

time for a test fit


someone mentioned I don't know how to weld aluminum.... this wasn't me, it was magick

then weld in the stand

then install the hood

some say I don't learn - I say, see the hood and I'm checking clearance before I build the top piece? yeah, lurnin'

and it clears... woo and hoo!

time to cut out the top pieces

then time to temper the metal


soot

and then I question why I didn't pick up 5152 or 3003 aluminum on Friday...


I'm going to try to bend this around but I give it about a 30% chance

[SuperBuickGuy]

little further... the holder for the air cleaner
bought some 1/4"x3/4" aluminum bar

the last step after welding was positioning it in place

[SuperBuickGuy]

time to make it out of metal

now with sides


and test fit with the cover

tomorrow, weld and do the cover

[65RHDEER]

Looks great SBG, another quality part on the vette

[SuperBuickGuy]

first... trim the tray to make more sense then do a first piece

then a top piece

next side panels


other side.... keep in mind the motor is off-centered from GM so steering and brakes can be in the engine compartment... not as noticeable until you do something like this

finished product.... well, finished CAD


tomorrow, make this out of aluminum

[SuperBuickGuy]

tonight we start with CAD work

panels

and enclosed

and then some envisioning tape


now just to make it out of metal

[SuperBuickGuy]

lower valence installed

this removed. I don't need it. Called Derale today, we talked about what I was doing and cleared up a misconception..... that they are computer controlled motors. They're not in this case, it's a 2 speed motor thus I can control it with my Holley computer. Key here, if you're copying, is you MUST start the fan on low speed then double the speed by adding power to the high side of the motor.

and wired

With substantially tuning, it's drivable now
but
I still need an air cleaner

hmm

probably this

all i have to do now is build it

[SuperBuickGuy]

List to finish this round

1) finish fan system - that includes a switch to power the fan and the water pump while I'm sitting between rounds
2) attach the side pipes
3) wrap the sidepipes
4) make it so the gas tank can't slide in its straps (yeah, really)
5) tow hooks
6) reinstall interior
7) build air cleaner
8) tune....
9) build rear cover/defuser
10) install front spoiler


*eventually build an exhaust system that's side pipe but actually doesn't kill power and is tunable
*put dual adjustable coilovers

[SuperBuickGuy]

time to finish up the cooling system

plumb the tank

first, paint the mount

then the layout

Thursday, the stainless upper hose was in progress. Needed a bleeder as this is the highest point

because the metal is only 16 ga, I put a plug in the top then tapped it for the bleeder

finished here


you know, I could have finished this all pretty, but f*** that - gotta give the haters something to hate on

then a solid aluminum tube for the lower hose

once mounted
time to connect the AN side

on unfinished tasks.... painted the lower valence

we end on my favorite task... wiring... it was comforting to read that my plan will void the warranty

this isn't the void part... but I can't imagine putting the controller on the bumper support is a recommended procedure

grounding done (now we're voiding)