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Old 08-26-2014, 11:44 AM   #361
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For the rubber trim go to McMaster-Carr. That's where I got mine:
McMaster-Carr
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Old 08-26-2014, 12:49 PM   #362
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LOVE the stick and cardboard method for making a cold air box that follows the hood contours! I need to try that out.
I actually found it here on MiataTurbo in a thread from like 2009. If you try this, just make sure you use single thickness cardboard and cut the skewers in half. Too long a skewer means too much friction and you will end up going back and forth a million times slamming the hood. Also, put skewers in the corners. My interpolation of the data points was somewhat inaccurate in that area

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For the rubber trim go to McMaster-Carr. That's where I got mine:
McMaster-Carr
Bitchin' link, thank you sir. Props! McMaster probably has the heavy plastic I'm looking for as well.
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Old 08-26-2014, 05:19 PM   #363
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Jeffbucc: Where are you buying your ABS sheet?

Searching for plastic sheet on McMaster-Carr is somewhat frustrating. The most "useable" things I can find are "High-Temperature Chemical-Resistant CPVC" and "Wear-Resistant Nylon." These are the only things I can find that are remotely affordable and available in the size I need. Again, I'm not worried about temperature resistance per-se, my header is wrapped and this thing its going to get insulated half to death once I fabricate something I like.

Also, I just realized there is no room for the IAT sensor in the box. That's unfortunate :(
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Old 08-26-2014, 05:25 PM   #364
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I buy mine from a local advertising & print shop in town. They will order pretty much anything I want. Good folks. I had to call about 10 different business before I found one that would order it for me at their cost.

Why not put the AIT in your intercooler? Seems like you'd have more problems with heat soak with it in the engine bay.
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Old 08-26-2014, 05:35 PM   #365
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Why not put the AIT in your intercooler?
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Old 08-26-2014, 05:38 PM   #366
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Took me a second to realize how unconsciously clever I just was.
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Old 08-26-2014, 05:51 PM   #367
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I'd recommend aluminum sheet for bending up that air box. It looks like you have some tight clearances to deal with, and it's easier to reproduce sharp bends with aluminum (ABS is thicker and will have more curvature in the bend). I built a nearly identical air box for an NA. See HornetBall's Build #2: Meet Red and HornetBall's Build #2: Meet Red for pix in the red car build thread.

I also mounted my AIT to a piece of aluminum angle and then riveted the aluminum angle to an interior wall of the air box so it sees the same temp as the air filter. It works just fine for speed density.

We need to be looking at each other's build threads since we're building similar normally aspirated cars.
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Old 08-26-2014, 06:11 PM   #368
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I refuse! I am a special and unique snowflake!

I have seen your build thread, and your ability to fabricate with aluminium far exceeds my ability to fabricate with aluminum. I have zero tools to this end. If I can't do it with a hammer, drill and a hacksaw, its probably not going to happen at this point. I have a feeling heat gun and ABS is about as good as its going to get for now :(
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Old 08-26-2014, 06:34 PM   #369
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It's all good. But practice with a small piece of ABS first. When I did my upper radiator piece, I was really surprised at how much heat it took and also by the radius of the bend. Jeff seems to have come up with a way to make tighter bends, so it's doable but might be frustrating.

Working with aluminium (LOL) is actually much easier than you think. Having a sheet metal brake is awesome, but if you have a vice, a couple of pieces of angle iron and a body hammer you can get really good results.

Looking forward to the end product!
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Old 08-26-2014, 07:00 PM   #370
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Oh for sure, aluminum is absolutely where I want to be in the future. When I finally get the EFR in there will be an orgy of fabrication and I'm sure I'll have to buy some more tools. All this N/A business is temporary just to get things squared away for Miatas@MRLS. In fact, there was a little voice in my head that wanted to spray paint the cardboard and see if anyone noticed

I've got 9 days to finish this mess. Plenty of **** left to do, I'm just trying not to cut (too many) corners at this point. Big hump is the CAN bus wideband controller, and I'm hoping to start that install tonight.

That reminds me... I need to call the idiots at Skunk2 back. They "promised" I would get an email back about my IACV adapter for the throttle body. I deal with tech and often, broken tech and retarded software for the vast majority of my job. This is one of the stupidest processes I've ever had to deal with trying to get a replacement part that was mispacked at the point of origin. Seriously, dealing with these people is like dealing with a mom n pop shop in the 90's that isn't using computerized records and the majority of their workforce is interns. ******* ridiculous.
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Old 08-26-2014, 07:04 PM   #371
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Well, if you're in a rush, Emilio runs the 95R without an airbox. Runs Crusher with a 180 degree bend to the cold side. So, if it turns into a PITA, not something you need to finish 100%.
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Old 08-26-2014, 07:17 PM   #372
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Well, if you're in a rush, Emilio runs the 95R without an airbox. Runs Crusher with a 180 degree bend to the cold side. So, if it turns into a PITA, not something you need to finish 100%.
Agreed. I run my 99 motor with vvt and Megasquirt (at least before the ms dun blewed up) with just a filter on the end of a tube. No issues with heat soak or loss of power especially once the car was moving. I'd consider your air box extra credit.
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Old 08-26-2014, 07:18 PM   #373
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Yep, Its something I've considered. I'm pretty sure the statute of limitations has expired, but yeah, none of the 4 cars we ran at the 25 had any sort of ducting for the intake. Of course, its dangerous to copy purpose built becauseracecar configurations

If I decide I have more dollars than sense, I can always order the RacingBeat elbow intake and heatshield.

As always, I appreciate the feedback. Thanks Hornet!
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Old 08-26-2014, 08:33 PM   #374
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The ability to make tighter bends with ABS was just a pleasant byproduct of trying to get a straight bend when heated. I was scoring it /16 deep and a beveled edge to encourage the bend to follow the path of least resistance. Turns out that is how you get a tight bend too!

Just be careful you have enough heat otherwise it will snap instead of bend. It also helps if you can find a block of wood or something with a 90 bend in it, then grab a rubber mallet and help shape the plastic into a edge more than a curve.
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Old 08-27-2014, 01:10 PM   #375
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I made this without any crazy special tools. Just some, uhh, "municipal" aluminum and a small HF brake.
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Old 08-27-2014, 01:20 PM   #376
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that looks great. I need to stop bying heat shields and start MAKING heat shields lol
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Old 08-27-2014, 01:33 PM   #377
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Well, ****. Maybe I need to visit the harbor freight and see if they have one of those brakes in stock.

Also, lol @ "municipal aluminum"

I got absolutely nothing done last night, other than breaking the wife's Nexus7 Tablet. /sigh
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Old 08-27-2014, 01:40 PM   #378
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Quote:
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and a small HF brake.


Wait, one of these ones? How small is small? They have an 18" and a 30" version of this particular brake
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Old 08-27-2014, 01:51 PM   #379
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So here is my issue: with this gasket in place, I cannot reinstall the lower manifold brace. I can probably make a spacer of appropriate thickness to fit between the brace and the block to make things line up again, but I'm on the fence as to if I actually "need" the lower brace or not. With the aggressive engine mounts, the vibratory nature of the BP, and the possible compression of the plastic spacer I'm concerned with long term durability. The last thing I need is the manifold coming loose and causing vacuum leaks from hell.

Anyone with any insight into this particular set of circumstances? It's not beyond my ability to create problems that do not exist, but I'd like some feedback if just to prove I'm (not) insane.
I'm a few days late on this one, but I've had 4 miatas now and one of the first thing I've done on every one of them is throw that stupid brace away. I ran that same intake manifold gasket on my '99 and my '94 for probably 40k miles total and never had any vacuum leaks with it.
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Old 08-27-2014, 02:37 PM   #380
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I don't use the braces either. They get in the way of reroutes and the big oil filters I like to use with my oil cooler parts.
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