CIH Turbo EFI by RallyBob

[RallyBob]

Some of the improvements, showing the new heater core, lined heater box, revised coolant inlets and outlets (made from copper pipe), and all components cleaned and coated with truck bedliner for sound attenuation and as a thermal barrier to keep the heat in. Note the new foam seals everywhere, the stock stuff was non existant, having dried up and crumbled off. Less leaks equals more efficient heat transfer.

[RallyBob]

Today I got a new intercooler core for this project. Yes, I already had a WRX intercooler, and had modified it already, but when I went to test fit it earlier this week with an engine block in place and the radiator fitted, the WRX intercooler just wouldn't fit (too tall). I said screw it and got a new core, and will fabricate the end tanks from scratch. This new intercooler core is longer, but shorter in height, so it will provide the clearance I need. It will also allow for more horsepower potential, and with greater safety for the engine.

[asdasc]

Bob, what you did to that heater box is beyond anal retentive, that is a work of art. I was wondering when you said you spent 3 days on it.

I never thought I would be jeolous of another mans heater box....

[namba209]

As always Bob, and I've said it numerous times, what you're doing is an art form. I can emphasize with you on the cooler. Margaret has oft told me working on a prototype is sometimes a real PIA. Next week the AC compressor brackets get built, I hope, depending on welder availability. Then the real fun of building an airbox to go to the throttle body from the Lenk Tuning Hood nostrils via a K & N air filter, with some sort of rain diverter in the mix. The only thing between what you do and what I do is skill, workmanship and aesthetics, your stuff looks much much better, by far, real far. Definately inspirational.

[RallyBob]

Originally Posted by asdasc Bob, what you did to that heater box is beyond anal retentive, that is a work of art. I was wondering when you said you spent 3 days on it.

Thanks. Wait until you see the defroster duct I made from aluminum! I need to take some pics of it, it's all done except for the upper flanges. I'm actually kinda proud of this piece of work, too bad it will be completely hidden under the dash!

Bob

[BQS4]

Bob;
Where did you get the little bead seal for all the edges of the heater box and all?

[RallyBob]

Originally Posted by BQS4 Bob; Where did you get the little bead seal for all the edges of the heater box and all?

I found a huge roll of it in my dad's (woodworking) shop. I guess it's some kind of window seal material, left over from when he had a window/door business too.

If you want some, let me know, we have a ton of it. Just used contact adhesive on both surfaces, and voila....no more air leaks, and no sticky/gooey mastic sealer either.

[BQS4]

Originally Posted by RallyBob I found a huge roll of it in my dad's (woodworking) shop. I guess it's some kind of window seal material, left over from when he had a window/door business too. If you want some, let me know, we have a ton of it. Just used contact adhesive on both surfaces, and voila....no more air leaks, and no sticky/gooey mastic sealer either.

Works for me.
Gene Smith
1665 Norton Estates Circle
Snellville, GA 30078

[tekenaar]

Originally Posted by namba209 As always Bob, and I've said it numerous times, what you're doing is an art form. I can emphasize with you on the cooler. Margaret has oft told me working on a prototype is sometimes a real PIA. Next week the AC compressor brackets get built, I hope, depending on welder availability. Then the real fun of building an airbox to go to the throttle body from the Lenk Tuning Hood nostrils via a K & N air filter, with some sort of rain diverter in the mix. The only thing between what you do and what I do is skill, workmanship and aesthetics, your stuff looks much much better, by far, real far. Definately inspirational.

Definitely true . . . but, once and for all, definitely NOT definately!

[RallyBob]

Originally Posted by BQS4 Works for me.

Packed up and ready to go out tomorrow morning Gene. I probably sent enough for 3-4 cars BTW. If you have any questions on application of the foam, particularly at the diverter flap, let me know. That part was a bit of a PITA to fit, since with contact adhesive, once it's stuck...it's stuck.

[BQS4]

GREAT!! Then I can do my wife's Wagon too. She's driving it regularly now and I can pull the heater unit off this summer and redo it for better heat next winter. You didn't put that thick padding back on around the heater unit, you just used the "rhino liner" stuff correct?

[RallyBob]

Originally Posted by BQS4 You didn't put that thick padding back on around the heater unit, you just used the "rhino liner" stuff correct?

Correct, I used the spray-on bedliner. Between that and the aluminum tape I used inside the heater, the heat transfer is greatly improved. I tested it with a heat gun and an infrared pyrometer.

[RallyBob]

Okay, here's the defroster duct pics. Not quite done yet, but not much left to do. I polished the interior surfaces before welding the two halves together, then the outside will get the bedliner treatment. This should aid in keeping the temperature high within the ductwork and improving the Manta's notoriously crappy defroster system. Not to mention the days of cracked defroster duct tabs is over.


I started by tracing the stock plastic duct shape onto two pieces of 3/4" solid wood (I used poplar). I cut out the two shapes, one to the exact dimension, the other approximately 1/2" smaller overall.

Then I used a 3/8" radius round-over router bit to create a radiused edge to the piece of wood that was the same size as the duct.

A piece of .050" thick aluminum was clamped between these two pieces of wood, and I proceeded to hammer the edges of the aluminum to wrap around the radiused wood edge. I should note that I first annealed the edges of the aluminum to make it more malleable, and used plastic hammers to avoid damaging the surface of the aluminum.

Another identical panel was made using the same hammer-form technique, and then I trimmed the edges of the panels with aviation snips, and filed them smooth.

Next step was to polish all the inside surfaces of the two aluminum panels, and then to clean them well and weld them together.

The final steps are to finish-weld the top flanges I made in place, and trim the overall length of the duct, then spray the bedliner coating and install.

[asdasc]

Bob, I am guessing you spent more time engineering and testing than the guys at Opel did 30 years ago. A heat gun and a pyrometer....too cool!

It is one thing to look at it and try to add something to make it better, but then to do validation testing prior to reassembly is going the extra mile. I am sure you took notes on the before and after data so that you can refer to it later!

From now on, if you do two of everything you do, and auction off the spare, you will live a life of luxery!

[opelwasp]

could you send any of that foam strip my way,Bob? my 74 manta is in dire need too?

[GoinManta]

Originally Posted by RallyBob the heat transfer is greatly improved. I tested it with a heat gun and an infrared pyrometer.

Thats nuts... I cleaned core and a properly lubed fan runs me out of the car as it is.. I guess its hard to disagree with you stating your anal retentive..

Charles

[GoinManta]

Originally Posted by RallyBob Okay, here's the defroster duct pics. Not quite done yet, but not much left to do.....

Everyone please let me introduce Bob Legere the Chip Foose of Opels

Charles

[GoinManta]

Speaking of which.. ever contact Foose for a job.. YOU would seem to fit right in with his style, and attention to detail and fabrication..

[2 Fast 4 U]

Just when I was thinking that nothing could impress me anymore, he just does it again