More putty. It doesn't look like much, but this is about 10 hours of work since the last photos!
Sunday, February 24, 2013
Wednesday, February 20, 2013
Sunday, February 17, 2013
I took the coolant reservoir sphere to Lewis Welding for the last weld.
I have been asked why I don't do my own TIG welding, since I'm a hardcore DIY guy when it comes to everything else. This is why; I will realistically NEVER lay down a bead of weld this nice.
Into the lathe
Ready for finishing and paint!
I made this magnetic iPhone mount so I can take pictures and videos without using my hands.
Back to bondo!
I have been asked why I don't do my own TIG welding, since I'm a hardcore DIY guy when it comes to everything else. This is why; I will realistically NEVER lay down a bead of weld this nice.
Into the lathe
Ready for finishing and paint!
I made this magnetic iPhone mount so I can take pictures and videos without using my hands.
Back to bondo!
Thursday, February 14, 2013
After the final fitting of the coolant reservoir, I welded the mounts into the strut tower.
The next step was to plumb the coolant inlet through the firewall.
Some test-fits
I made this aluminum o-ringed plug on my lathe. I need to make a large enough hole to pass the flare fitting through the firewall, so I can't use a regular rubber grommet.
.780" hole drilled, which should be large enough to clear the 11/16" hex on the flare nut.
There is an O-ring and retaining ring on the inside to hold everything in place.
Back to bondo! I laid a coat of Evercoat Tiger Hair, I should be spreading regular filler this weekend.
The next step was to plumb the coolant inlet through the firewall.
Some test-fits
I made this aluminum o-ringed plug on my lathe. I need to make a large enough hole to pass the flare fitting through the firewall, so I can't use a regular rubber grommet.
.780" hole drilled, which should be large enough to clear the 11/16" hex on the flare nut.
There is an O-ring and retaining ring on the inside to hold everything in place.
Back to bondo! I laid a coat of Evercoat Tiger Hair, I should be spreading regular filler this weekend.
Sunday, February 10, 2013
It's been just over a year since we scrapped Papa Fazz's old Ford, we have gone without a truck for too long! I bought myself a new 2012 Chevy Silverado 2500HD, with the 6.0L gas engine. This also means the Jetta will be a trailer queen.
It's about as long as a city block.
6 Liters of gas guzzling power. 'Merica.
After almost destroying my hemisphere trying to fit the mounting bosses, I decided to do it the easy way this time. I plunged a 7/8" diameter end mill through for a perfect fit.
Kage is forklift certified, so he helped with the heavy lifting.
To fit the mounting bosses, I got some help from Solidworks. I modeled each tube and printed an un-wrapped profile.
Much better than last time!
I had it welded up.
No burn-through to the outside for a perfect smooth look.
Pressure tested. My ghetto pressure testing fixture leaked like crazy, but the welds didn't!
I started fitting the new reservoir to the shock tower. I tacked it on the outside during mockup, but it will be welded inside the wheel well for a clean look in the bay.
I put the hood on for a rough clearance check of the new reservoir location.
Tacked in place.
It's about as long as a city block.
6 Liters of gas guzzling power. 'Merica.
After almost destroying my hemisphere trying to fit the mounting bosses, I decided to do it the easy way this time. I plunged a 7/8" diameter end mill through for a perfect fit.
Kage is forklift certified, so he helped with the heavy lifting.
To fit the mounting bosses, I got some help from Solidworks. I modeled each tube and printed an un-wrapped profile.
Much better than last time!
I had it welded up.
No burn-through to the outside for a perfect smooth look.
Pressure tested. My ghetto pressure testing fixture leaked like crazy, but the welds didn't!
I started fitting the new reservoir to the shock tower. I tacked it on the outside during mockup, but it will be welded inside the wheel well for a clean look in the bay.
I put the hood on for a rough clearance check of the new reservoir location.
Tacked in place.
Thursday, February 7, 2013
I did some more work on my coolant reservoir this week.
I ground the weld and pressure tested the coolant inlet nipple.
Last week I made a ring for the cap, which I had welded on and then put back in the lathe for finishing.
Before welding:
Welded
Turned.
It presses inside the Billet Specialties cap.
This is how the top of the reservoir will look.
I cut a hole through the side for the coolant inlet, all the welds will be inside the sphere so it will look clean.
-10AN fitting out the bottom
-6AN fitting and cap in the top
Next I did some figuring to lay out the 3 mounting bosses.
I used the lathe to help layout the lines exactly 1" apart.
The mounting bosses
During the final fitting, I fucked it all up. The holes ended up ovalized and the gaps were too big, so I had Bill build up some weld so I can try again. I ordered another hemisphere, but I think I can fix this one.
I also destroyed one of my mounting bosses trying to saw it off.
New mounting boss to replace the gouged one:
After laying everything out a little better, I'm starting again. This time it should be more symmetric with tighter gaps.
I ground the weld and pressure tested the coolant inlet nipple.
Last week I made a ring for the cap, which I had welded on and then put back in the lathe for finishing.
Before welding:
Welded
Turned.
It presses inside the Billet Specialties cap.
This is how the top of the reservoir will look.
I cut a hole through the side for the coolant inlet, all the welds will be inside the sphere so it will look clean.
-10AN fitting out the bottom
-6AN fitting and cap in the top
Next I did some figuring to lay out the 3 mounting bosses.
I used the lathe to help layout the lines exactly 1" apart.
The mounting bosses
During the final fitting, I fucked it all up. The holes ended up ovalized and the gaps were too big, so I had Bill build up some weld so I can try again. I ordered another hemisphere, but I think I can fix this one.
I also destroyed one of my mounting bosses trying to saw it off.
New mounting boss to replace the gouged one:
After laying everything out a little better, I'm starting again. This time it should be more symmetric with tighter gaps.
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