Nothing to see here, just project Sisyphus, move along
08-26-2014, 11:49 AM
#362
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For the rubber trim go to McMaster-Carr. That's where I got mine:
McMaster-Carr
McMaster-Carr
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08-26-2014, 04:19 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 :(
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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08-26-2014, 04:25 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.
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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08-26-2014, 04:51 PM
#367
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 https://www.miataturbo.net/build-thr...7/#post1129353 and https://www.miataturbo.net/build-thr...6/#post1156388 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.
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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08-26-2014, 05:11 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 :(
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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08-26-2014, 05:34 PM
#369
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!
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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08-26-2014, 06:00 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.
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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08-26-2014, 06:17 PM
#372
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08-26-2014, 06:18 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!
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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08-26-2014, 07:33 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 ¹/16 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.
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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08-27-2014, 12:33 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
Also, lol @ "municipal aluminum"
I got absolutely nothing done last night, other than breaking the wife's Nexus7 Tablet. /sigh
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08-27-2014, 12:51 PM
#379
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.
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.
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