Jacob's goon build

[DRIVEN]

^^^That's good stuff.

[Laecaon]

Today, mount the radiator. Hopefully will have pictures...

[Laecaon]

Ok got out there and realized that is not going to happen yet. I need to finish the intercooler holes in the core support first as the radiator brackets I have in mind will interfere with the work. But I do have some progress, passenger side is nearly finished, hoping to have it done tomorrow and well started on the drivers side.

First order of business was to increase the flow for the intercooler. Because the tubes of the intercooler hang below the inlet/outlet, it would have had about an inch being blocked by the core support. So I did this controversial (at least in my mind) thing.



And here you can see open frame rail. Please take note of the rust inside. My car is not a rusty car, so to see this is weird to me. Take notice and think about painting inside your rails. Eastwood makes a kit, and their are plenty of holes in the frame rails for drainage purposes.



Had to do the half round in two pieces so I could weld it to the middle piece of metal in the previous picture.




Here you can see the a more or less finished ish corner. Its all rather weird, but I will try to take better photos when its all finished showing how it looks from all angles.


And now notice the how much metal has been removed on the left side of the radiator opening. Yes the Core support in super flimsy, yes I will address that. All about that air flow!

[Laecaon]

Also, that is in no way the final face of the core support. Things be changing.

[izzo]

Strange. Cometic is one of the preferred gaskets on what I've been wrenching on. But bikes are a different ball game.

[Laecaon]

They make the cheapest MLS gaskets. They also dont use the technology of any other main brand. I could get an ACL, HKS, Greddy, Tomei and probably a few others. Im actually tempted to try and find an ACL one as its supposed to be a better design and cheaper...

[Laecaon]

Ok, so no more fab work today. Went to the car show. Got back and the winds and rain said to keep the garage closed.

So the only thing I did do was cut off the chunk of aluminum I needed. Marked out my lines. Placed a straight edge down as a guide, and let my skilsaw rip!

I used my Craftsman 2.5HP 12Amp skillsaw with a 24 tooth lumbar blade. Did it in 2 passes with each about .75" deep. The plate is 1.5" thick. Went decently fast, medium pressure, mostly just letting the blade do the work. I used PB Blaster as coolant ish, helps to keep the teeth from gumming up the aluminum. FYI its a super big mess.

I had to do this as my shop oddly enough doesnt have the ability to cut plates, only tubes/rods.

[Laecaon]

Took the plate to work. Started roughing the outside dimensions. Kinda hard to do when just using your break time... I get my holesaw tomorrow... I hope by the end of the week or early next week I will have it done...

Also my shift at work is advancing 2 hours later again, so 4pm to 2:30am. I think I will end up having more time in the day...

[Laecaon]

So started to make holes... I got my 3 3/8" hole saw and arbor. Right off the bat I realized the arbor is bent, fuckit. Went to town anyways. Got 2 holes cut, and on the 3rd the arbor broke. So I need to buy a new one tomorrow. Those first two holes look terrible, but whatever its not important. Its nice being able to set the spindle speed and have it be so solid. Also having a few types of cutting fluids (real ones like Cut-Max, and Alumicut, and Cool Lube...) helps out. I should have it all finished up tomorrow (thursday), at least Im really hoping so. And if that is the case, I should be able to take the block into the machine shop... because I also got paid...

[Laecaon]

And pictures finally. Plate goes on block, even managed to get the locating dowel ring things to line up. I need to finesse one of the holes a bit. It just barely doesnt provide enough clearance.

[Laecaon]

Also, I do this thing, where I write about things I need to buy. Like I was writing about things I still need to put the motor together.

Well, then that prompts me to search the parts to see the actual prices. Then sometimes I buy them... Like I just bought a gasket kit for a 88 Pulsar NX which has the CA18DE in it. All gaskets are the same, but its missing the Turbo specific stuff. OOO and this will let me measure the bore of the head gasket...

So to conclude my list:
- Water pump
- Timing components (Belt, tensioner, idler), and because I dont like any of the brands for the regular timing belts, Im gonna get a Gates Performance one...
- Finish the oil pan
- Finish pickup tube
- And of course all the machine work.
- Cometic head gasket?

Also thinking of trying a real assembly lube since it will probably be a bit before the motor fires up.

I guess I am playing a game with myself of seeing what to buy next, as to provide myself with work to do on the many facets of this project. So that means timing components will probably be some of that last parts to buy for the motor itself.

Like I need to start the fuel system... and the battery relocation... and the electrical... and and and... All things to do while I accumulate and spend money.

[DRIVEN]

Any chance we'll be seeing this at Canby?

[Laecaon]

I would like that very much...

[Laecaon]

Ok, got a decent amount done today. Drivers side intercooler opening completed, looks like passenger side... Just need to figure out how to grind down a few spots.

Then it was onto the radiator. I was working with one idea for the lower mounts, which I originally thought was going to strengthen the core support, but then it took too much space, and where it was going was already pretty strong feeling. So I changed, and I like it a lot more now, super simple. Then it was just getting the Radiator to sit at a height I liked. Need to grind down one of the welds on the rad, and it will fit perfectly, hood clears fine too.

Basically, the plan for mounting is this, lower mounts are rigid with little stops that keep the rad from moving away from the core support, plop the rad down on them and then swing the top of the rad in. Then, the top will be getting some clamps made that will pull the rad into the core support. So 2 bolts, and the rad can come in and out.

Lower mounts tacked in:


And how the radiator will mostly sit (it will come in a bit on top).








I got a little more done after that. Start to get the core support to its final shape.

Need to figure out the top intercooler mount. I will probably use that mount to strengthen the core support.

Also, gonna order the aluminum elbows for the intercooler to have welded on. Should help increase flow over silicone elbows, and well help make everything look more tidy.

[Laecaon]

Much to my relief, the Beck/Arnley head gasket will work! That means I save money on buying a MLS head gasket, and machine costs for surfacing the head and block. WOOHOO! I think that also means, I now officially have enough money to drop my block off at the machine shop...



I also got some other parts that will make a later appearance.


And then I was looking at things I had in the garage. I have enough stuff in the garage to last quite awhile. Like power door locks and windows for the rear doors, Actually getting the keyless functional. Redoing my relay/fuse panel because I dont want to do a motor swap with ugly wiring. Still need to make my battery box and order supplies for relocating it. And supplies for all the fuel related things. Also I think maybe more pressing... transmission...

[DRIVEN]

Good news is good.

[izzo]

I can't thumbs up this enough dude. Love it!!

I remember the whole story of this car.... Where you started off, where it went.. what happened, and now where it's going again. I rikey it a lot.

[Laecaon]

Made some brackets to anchor the top of the radiator in. Still need to drill/tap holes. Already the Radiator fits in the core support snugly. Core support even feels stronger with it in.

I also started bending a flange on the passenger side radiator opening. Way stronger now. Im liking where its at, starting to feel like its just finishing touches on the core support, well besides finishing the drivers side...

And finally, I finished up the torque plate, and torqued it down.

[Laecaon]

Block and pistons dropped off at machine shop. Said about 2 week turn around, perfect I got paid today and again in two weeks. He was also kinda shocked to see the torque plate, even saying "impressive". It actually looks pretty good with it installed and using the DOM spacers and head studs.

[Laecaon]

Discussed with a friend. Middle part of the top of the core support is going to be removable. Because why not? I figure with a stitch welded engine bay, and my plan to now run a strut bar (I know the merits or lack there of), it wont go out of whack. And it will just make everything easier.

Now to do the dirty work, and also make it look good when finished, and work with my radiator anchoring.