The re-designed intercooler placement takes shape. New end tanks have to be made, both because there’s not enough space for the previous ones, and as my buddy Alan reminded me, with around 20 psi boost pressure, that ends up being hundreds of pounds of force. Given a chance, that force would flex any flat-sided tank, work-harden the welds and cause them to crack; the new tanks will be cylindrical to avoid that. After taking these pictures, I changed the tube routing on the inlet side. As shown, the flow would have had to take a very tight 90-degree turn right out of the compressor, which is terrible for flow. The turbo outlet will be rotated to point downward and the flow will instead be fed through two large-radius 90-degree bends feeding into the center of the end tank from below. It’s also cheaper because the U-bends are already on-hand.
What will be decided later is where to get the cooling air from. Which approach to take will be determined with some test drives, string on sticks to determine flow direction, and clear U-shaped water-filled tubes serving as manometers to determine relative pressure. Regardless where it comes from it sure is going to change the appearance of the car – so be it.
The new engine is slowly coming together; shown is a coated piston. This week, the pistons, pins, and rods will be sent to ERL where the block will be honed and the short assembly clearanced and balanced. After that it’s back to the engine builder to add the inspected cylinder head and then we’ll be back in business. Reminds me that I need to send the head and various parts to the engine builder pretty soon so that I’m not holding up anything.
In other news, as seen from above, the driver’s right-hand shoulder belt bracket was found misaligned but wasn’t loose – I didn’t set it that way. Seems the spin at Willow may have been more forceful than I thought and with the car spinning to the right and catching the dirt bank, I apparently tried to keep going toward the left. It’s crossed my mind a few times that the HANS may well have prevented some serious neck injury.