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  #301  
Old 10-12-2017, 12:23 AM
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CarterKraft CarterKraft is offline
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Pfft some boost should straighten the air flow out.

Where the down pipe is closer to the fuel lines do you have any plans for that in the way of insulation? I used Al foil tape on the lines on my dad's suburban cause I was stressing about it a little, no idea if it helped or even mattered.
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  #302  
Old 10-12-2017, 09:41 AM
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juicedz4 juicedz4 is offline
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Quote:
Originally Posted by CarterKraft View Post
Pfft some boost should straighten the air flow out.

Where the down pipe is closer to the fuel lines do you have any plans for that in the way of insulation? I used Al foil tape on the lines on my dad's suburban cause I was stressing about it a little, no idea if it helped or even mattered.
Im planning on a ss heat shield, topped with some gold foil probably. They really arent THAT close, but I definitely still want something.

I have a plan for the ss piece, TBD if it works or not. So stay tuned I guess. hah


Dan
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  #303  
Old 10-12-2017, 10:15 AM
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Got some bonus garage time yesterday. Managed to get the charge pipe tacked up. I havent welded the elbow to the compressor yet, Im going to wait to do that once everything is together for realz.










Dan
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  #304  
Old 10-17-2017, 04:11 PM
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juicedz4 juicedz4 is offline
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Late last week I finally addressed the issues with the shifter relay bracket that mounts to the rack. Just like other people my Meyle rack wasnt made exactly right so the bracket was clocked wrong. Since the rack is already refinished I decided to modify the bracket. Adding a couple small pieces of 3/16" steel to the two mounting locations took care of the issue.





With that now fixed, it shifted the relay lever upwards and into the header. I figured this might be an issue, but I didnt want the header design to be constrained by the shifter figuring I could fix it easy enough.

Before



Sectioned



Bent the two pieces to match, welded a plate of 1/8" over the joint and smoothed it all out.





After :thumbup:




Dan
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  #305  
Old 10-23-2017, 10:42 AM
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juicedz4 juicedz4 is offline
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Had some free time sat am so I finished up the intercooler. I needed a filler but I hate inline fillers, plus I wanted it at the highest point so I added a neck right to the one end tank. A little section of aluminum tube, a 32mm neck, and Vibrant radiator cap did the trick. Also welded a -12 fitting for the inlet. Certainly not my best welding but the cast IC end tanks are certainly not the cleanest. It should look fine in wrinkle black powder.









With that done last night I made the mount for the IC pump. I started off with a $10 clamp which I cut up and welded to some 1/4" aluminum angle. Then welded a little box to the frame rail to mount it to.

Mount cut up (basically removed the mounting tabs) welded to some 1/4" angle and smoothed out.



Frame rail box made from 2" square tube with the end capped.



The assembly



Mount welded to frame rail and primed.



The whole smash mounted up.





Dan
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  #306  
Old 11-08-2017, 11:30 AM
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Back to work on this after an unplanned timing and water pump job on the Allroad.

Last night tackled the heater core return line. Its made from a stainless tube assy I bought off ebay. The one 45 I made as a two joint pie cut and then welded and smoothed to look like a 45. The only thing missing is a -6 fitting for the turbo water return but im currently out of stock.

Tacked up





Welded and smoothed. Again, just loving the Dynabrade. It makes short work of smoothing the welded joints





The smoothed out pie cut joint



Dan
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  #307  
Old 11-08-2017, 12:37 PM
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alwaysFlOoReD alwaysFlOoReD is offline
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Looks good!
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  #308  
Old 12-07-2017, 11:06 AM
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juicedz4 juicedz4 is offline
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Wow almost a month and no updates. I have been working on things just apparently forgot to upload pics and document.

I decided after doing all that work to get the 020 linkages and crap working I should swap to 02A transmission. :lol:

Picked up the 02A trans, 02J shifter, cables (which are wrong in this pic) from a friend. Also found a good 02J shift tower (no pics). And bought a set of S&P MK1 02A mounts.



Quickly realized that the shift box was going to be harder to fit with my exhaust setup. Not wanting to change the exhaust I spent so much time I it was obvious the shifter would need to change.



Pulled the shifter apart and started cutting



Made an aluminum cover. Its three pieces welded together and smoothed.





Perfect fit





With that done I switched focus to the alternator. Years ago I had planned to use a MK3 alternator, but the size of it and the position of the one plug just wansnt going to work with my new dual fan setup. I spent countless hours looking at images and sizes of alternators and finally found that a 2001 Jeep Wrangler Denso type alternator would fit the bill.

Machined a new top mount block on the mill at work. Then rounded off the edges on my router table.





And then cleaned it up with a maroon belt on the Dynafile.





Next was the lower mount / tensioner.

Clevis for the tensioner, using the rod end and adjuster I bought years ago. The clevis was made from some rectangular box tube I had laying around.





And after hours of screwing around I came up with this crazy bracket for the lower tensioner mount. I still plan to add some reinforcement to the sides, but its more or less done





It ties into the two mounts on the bottom of the block, and the water pump bolts.



Adjuster in place.



And mounted.





If anyone was wondering, I dont have a brake at the house for thicker plate so I whipped this up that I use in my vise. It works surprisingly well and way better than a hammer.



Next, it was time to figure out how to add a master cylinder to the factory pedal box. I looked at some ideas that others had done including fastbunnymetalworks and came up with something similar.



Made a bracket, again using my sweet brake shown above. its obviously not quite done, but very close. Hopefully Ill have it done this week.






That about catches up the progress on the project. Im sure I wont have a ton of time between now and new years, but Ill try to keep things updated should I move forward.

Dan
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  #309  
Old 12-14-2017, 04:55 PM
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juicedz4 juicedz4 is offline
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Finished up the clutch master tues night.

Added a small wedge on the right side of the bracket to tie it into the pedal box better. Also had to shift the hole in the pedal arm up half a hole to get the alignment perfect. Took the opportunity to fatten it up in that area so I dont need spacers in the clevis.

Ive since sandblasted and primed it. Ill blow some black paint on it tonight and itll be done. Of course I need to drop the pedal arms back off to be re-powder coated.

Welded nuts to the backside for easier in-car swapping.


Nutserts in the cowl area for the top mount.


Finished assy.




Dan
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