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Got the engine back yesterday. Need to take the cylinder head to a local shop to get it cleaned up and decked a little bit. I need to figure out the actual compression ratio first. Matt Kessler believes it will be 8.5:1 if the head is stock height (it's been shaved a tiny bit, but probably negligible). The pistons sit .008" above the deck at TDC, so will need thicker head gasket than stock (probably .045).
Finally starting to actually do something to the car. Got the intercooler in after a few emails back and forth with Lars. I'm usually really good at figuring things out without directions, but I was all aboard the struggle short bus with that for some reason.
For anyone installing an MK Turbo intercooler, you have to notch the brace for the hood latch a little bit.
Slightly crooked - not exactly sure why. Probably going to stick a washer or two under the bracket on the driver side to fix it. The bumper is all sorts of warped which makes it look worse than it is.
Also in progress, building a new splitter. 1/4" birch plywood that I'm going to wrap in carbon fiber, with a few pieces of foam "bars" embedded in it for added twisting strength. For the rear mounts, I think I'm going to weld a piece of 1/4" steel bar onto the subframe that will act as a hanger. The splitter will have two or three pieces of angle iron with matching notches that will slide onto it. The front braces of the splitter will hold it onto that. Hoping I can get this mostly done by the end of this week.
Progress has been pathetically slow on this because it's been so cold. Got the splitter done, just waiting to get the support rods for the front. It's going to be high 40's this weekend, so going to wrap it in carbon fiber either Saturday or Sunday.
Splitter looks good enough that I'm happy with it. Need to clean up the edges a bit still. Of course, if I could do it again I could get it near perfect.
Getting the cylinder head back in <2 weeks, so it will finally start going together.
Finally getting somewhere. Drilled and tapped the oil pan. Girlfriend painted it and the valve cover Ford tractor blue. Seemed appropriate. I also have the cylinder head back. Should have most of the engine assembled Saturday. Off next week to get it all close to done. Building at least one element of the wing on Monday.
Engine in. Need to rethink the intercooler piping. There's just no room with the sway bar I have to route it down that way, around the PS pump. Going to go over the radiator. Might do the same with the cold side. Tempted to do EPS like Leafy did, but not sure I have the time/energy/money to do it before the season starts.
Nest of snakes will get better as stuff actually gets hooked up.
Going the leafy route, and doing the volvo electric power steering pump. I didn't like any solution I could come up with that would let the intercooler piping work with the sway bar I have, keeping the headlight, and the PS pump. They all sucked pretty equally. Ordered a pump off ebay. Need to order the wiring harness, and figure out all the plumbing.
Did a bunch of wiring on the snow day on Wednesday. No idea why picture quality is garbagio. Not worthy of r/cableporn, but it mostly satisfies my OCD. Ran out of red wire, still need to wire up power steering pump.
Made a bracket for the PS pump:
Wiring a whole bunch of crap:
Need to figure out a different way to place the BOV. Obviously not going to work there....
12-06-2017, 02:04 PM
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