So, a few minor updates, I've mostly been busy ordering parts and trying to keep everything on the boil. Run into some difficulties fitting the rear coolant pipe, and the thermostat housing.
Solved that by turning the 'stat housing through 180' and welding a bend in the coolant pipe- will probably have to add a de-gas line to the stat housing in the future.
And the up-side down 'stat:
With that kind of done, I could get on with installing the cooling pack, as nothing can be left alone on this car, I wanted to tweak things slightly, continuous improvement and all that (also known as compulsive meddling).
So, few bits to consider for front end minor re-hash:
- Get rid of old bumper bar, most G40 owners with big intercoolers have hacked these to death, and they serve no purpose in a crash
- Make the front bumper easily removable (was on two 10mm bolts) for easy loading on the trailer
- Move the IC closer to the bumper, allowing ducting and a more efficient air path
- Move radiator forward allowing more space for alternative downpipe routing if required
- Make it all look race spec etc.
First up, sack the old bits off, and make some new end plates from 5mm sheet:
I'll make these slightly smaller and slighter in due course, then get a piece of CDS cut to length and bent:
Plug #1 :
http://www.tube-bender.co.uk/Tom who runs Tube Bender was a very nice chap, and affordable, also had the bonus of being a few miles away
After that I fitted the intercooler up, and tweaked its position:
The slight angle allows it to sit nicely against the bumper, speaking of the bumper this was then hacked to bits, holes drilled for catches, and bits cut out to shape around the IC:
And the semi-finished product:
Shut lines nee a slight tweak, but it slides on and off like a good 'un, so next bits are welding top tabs on for the IC and radiator supports, then boost hoses and coolant pipe routing.
I've also been busy with drive shaft manufacture and have chosen Elite in Stoke to make them:
http://www.eliteracingtransmissions.com/ not cheap, but I don't want to buy twice.
Also had several e-mail exchanges with Gordon from Ringspann, who was very helpful - unfortunately bespoke cables are far too expensive, so I've used these guys:
http://www.cable-tec.co.uk/ to alter some standard Mk4 Golf cables to length, I'll post results when done.
Cheers
Pete