All work....
 

and No Play.

Got a little overwhelmed with the amount of work for the rad mount that I figured I do something I could complete, mount the fuel tank!

http://forums.pelicanparts.com/uploa...1610940287.jpg

Drilling spot weld holes for the upper tank mount. I made plates with a threaded hole to weld behind the panel to mount the tank.

http://forums.pelicanparts.com/uploa...1610939713.jpg

Lower gas tank mount hole. The chassis leg is cut short and capped as the upper tank mount panel is missing (I never knew it existed until I saw some pictures of an RSR build here).

http://forums.pelicanparts.com/uploa...1610940131.jpg

I did have to weld a lower mount to the tank though. It was sort of stuck on with some glue but not for very well.

4 plates welded in and the tank will stay in place.

Hog Heaven with...
 

...Hole Saw!

http://forums.pelicanparts.com/uploa...1610940880.jpg

Figured there was quite a bit of surface area being blocked by the beam at the back side of the radiator, so poked some holes. Tried to make them look nice too!

http://forums.pelicanparts.com/uploa...1610941063.jpg

Cut off the 1/2 inch box sections pieces sort of holding the threaded inserts for the front suspension mount to the beam and added a more substantial bracket. Also started the new opening for the radiator by adding a 3/4 inch round bar across the front of the car.

Bashed Some Things Out
 

....Literally.

I recycled the puffy radiator after I poked a hole in it whist test fitting it in the car. It's one of the few times that I've ruined a functioning part and was not upset by it. It's for the best. However that did open up what radiator to use instead. I looked at lots of radiators, from DIY kits, stock radiators to custom built. I decided that what was good enough for Chevy should be good enough for me, so I bought an alloy aftermarket 2006 Corvette (after reading that the Chevy radiator wasn't actually that good). It had the right size inlet and outlet, was designed to lean back a bit with a lower hose that was a little higher in the tank, was about the right size to fit in the space. It was also readily available and I could use a stock AC condenser for the AC. Once it got here, I started to fit it in the car

http://forums.pelicanparts.com/uploa...1611806595.jpg

Made a lower radiator pan and upper cross brace that the radiator would sit in and lean against. It fits pretty will in there. Need to seal it in some how.

Front Pan
 

Duct, Duct,
 

Goose...

I have been looking at lot of simple and sensible set ups for ducting air through the radiator but being a simple yet un-sensible person, I decided to build my own.

http://forums.pelicanparts.com/uploa...1611889902.jpg


http://forums.pelicanparts.com/uploa...1611890131.jpg


http://forums.pelicanparts.com/uploa...1611890253.jpg

The fuel tank acts as the duct for the exit under the car (this may change), the vertical panel seals to the tank. The radiator drops down into the pan, is located by the pins on the bottom of the radiator and leans back into the diagonal panel. Air entering the front of the car and should be pushed through the radiator.

I finished the chassis leg too, tied it into the I-beam cross brace. I think it will work.

Goose, Goose,
 

Duct!

http://forums.pelicanparts.com/uploa...1611891080.jpg


http://forums.pelicanparts.com/uploa...1611891522.jpg



If I had a dollar for every time I wished I had just bought the Renegades Hybrid's duct and radiator and be done with it, I would literally have enough money to buy that set up several times over.

Amazing and impressed!

I can highly recommend NOT using the fuel tank as the back side of the duct to move air under the car.
I shaped my aluminum tank to serve as duct and have issues with fuel boiling. I have added multiple heat barriers bit it remains less than ideal.
Please consider a separate duct with a sufficient air gap to the tank.

Keep it up! In the end it's a fun car to drive.

Thanks for the insight, I could see that being an issue. I will see what options I have with the space available. I could build a bulk head forward of the tank with an air gap I recently decided that I was happy to cut a hole in the freshly painted hood and wished I’d lent the radiator forward and vented out the hood. Did you end up with a workable solution?

Cross Brace
 

or should it be Kross Brace?

Took a little time off from this car these last few weeks to get some good work done on another project. Decided to leave the rad for now and build a cross brace. Went with an RS style weld in mount on the towers and build a 3/4 DOM cross bar with ties to the radiator support. Left room in the middle incase I want to add a center fil to the tank down the line.

http://forums.pelicanparts.com/uploa...1613449678.jpg


http://forums.pelicanparts.com/uploa...1613449755.jpg

AC For Me?
 

I left room for the stock Corvette AC condenser which just slips onto the radiator. I am thinking of using the stock LS compressor and an under dash evaporator with heater. That's a bit further down the road yet though.

Hi, first let me say I really like your build! I'm currently building a '77 widebody and also have a BMW e30 M3 which I've highly modified and raced in NASA GTS.

http://forums.pelicanparts.com/uploa...1613739648.JPG

http://forums.pelicanparts.com/uploa...1613739182.JPG

I've also also run CFD (Computational Fluid Dynamics) on the car to get the best aero balance.

http://forums.pelicanparts.com/uploa...1613739371.JPG

I see a number of water cooled 911 conversions routing the radiator discharge air under the car. This will produce front end lift to an already light front end and could create a dangerous situation similar to hydroplaning. On my race car I actually moved the radiators to the rear and have the front intercooler air routed out of the top of the hood (black hole in the pics). This significantly helped the overall aero balance with the wing in the rear.

Depending on how you want to use the car once done, you may want to investigate other options for the discharge air.

....I can't find my venting ductwork....but here's a picture with the hood removed.

http://forums.pelicanparts.com/uploa...1613740285.jpg

Venting about Vents
 

I thought this might be an issue but figured it was the "normal" thing to do. I'm going to look at it this weekend, see if I can flip the rad forward and vent out the hood, or cut some side vents and dump into the wheel well. I haven't solved the fuel tank heating issue yet, but I think I have a workable plan in place.

I'd stay away from venting to the wheel wells as well. Best option is out the hood near the front. That location is a low pressure area and helps extract the air.

Oh nuts........
http://forums.pelicanparts.com/uploa...1614203979.jpg

http://forums.pelicanparts.com/uploa...1614204025.jpg

http://forums.pelicanparts.com/uploa...1614204091.jpg

I think I’m going to have to suck it and see. It’s not a dedicated track car, will mostly be street driven with a few track days thrown in for fun.

If you are willing to modify the fenders to allow for a rear vent...similar to this (uh...but without the text :confused: ) it would help. For a street car you may be fine with the side vents though.

http://forums.pelicanparts.com/uploa...1614260370.jpg

Got to Stop....
 

So a few set backs there, moving on to see if I can get a couple victories to boost the moral. Going to leave the cooling system for a bit and work on getting the car rolling again.

Gave everything a quick coat of paint and started to reinstall the front suspension.

http://forums.pelicanparts.com/uploa...1615247442.jpg


http://forums.pelicanparts.com/uploa...1615247618.jpg


Getting the control arms on and struts installed was pretty straight forward. Getting the brake ducts to clear was not so easy.

http://forums.pelicanparts.com/uploa...1615247802.jpg

This is what it looked like before. The duct hit the wheel every quickly when any amount of steering was tried, worrying all around who heard it when we first unloaded it from the trailer. We looked a bit like Austin Powers getting it into the shop, about a 30 point turn!

Big Brakes Are Cool
 

Did a little poking around the internet and saw that there were a few options for passing the duct through the control arm, so figured I'd have a go at that. Got some 3in split vent duct for a water heater from the hardware store and cut a test piece. A few snips here and there and a couple of oval hose and this might work.

Didn't love the duct intake at top rear position. Was able to swap them side to side and weld up a couple extra holes and get them positioned under the steering arm. Pretty happy with the outcome, I know they are not the most efficient thing, but got to be better than nothing.

http://forums.pelicanparts.com/uploa...1615248682.jpg


http://forums.pelicanparts.com/uploa...1615248809.jpg


http://forums.pelicanparts.com/uploa...1615248998.jpg


http://forums.pelicanparts.com/uploa...1615249067.jpg

Pretty Happy with this set up, seems like it might even stay on for a couple hundred miles before something rips it off!

The observant amongst you unfortunately win no prizes for noticing that I cut the vents after the brakes were on. But good looking out anyway.