Firewall Project
 

I'm ready to rebuild the firewall. I cut the flanges out today for the intercooler tubes to pass through the firewall. I'll turn them down on the lathe & weld them in place & shape the sheet metal around them.

http://img.photobucket.com/albums/v2...ewallstart.jpg

http://img.photobucket.com/albums/v2...llFlanges1.jpg

http://img.photobucket.com/albums/v2...llFlanges2.jpg

Re: Firewall Project
 

Got the flanges turned this weekend.

http://img25.imageshack.us/img25/8913/flangebore.jpg http://img25.imageshack.us/img25/fla...jpg/1/w850.png

I put a groove around the edge of the flange for the firewall sheet metal. Once I install the o-ring and get in place I'll check the new gap with a feeler gauge and make a soft gasket to seal the flange to the firewall

http://img196.imageshack.us/img196/8...flangeclea.jpg http://img196.imageshack.us/img196/f...jpg/1/w850.png

Re: Firewall Project
 

Engine side of the flange bored to size for the tubes.

http://img36.imageshack.us/img36/7459/flangetubefit.jpg http://img36.imageshack.us/img36/fla...jpg/1/w850.png

Got everything mocked up. The flanges on the windshield will be added to the inlet side. I'll turn those once I get the V-band clamp. Should be here any day. The outlet side attaches to the carb bonnet with hose & clamp.

http://img194.imageshack.us/img194/4...esmockedup.jpg http://img194.imageshack.us/img194/f...jpg/1/w850.png

Re: Firewall Project
 

No "flex" joints?

Re: Firewall Project
 

Yes, they will be beyond these. This is to get the tube through the firewall only.

Re: Firewall Project
 

Made a little more progress. I put the ol' foam mock up engine in it to make sure I get the angles right before going too much further. (Joint will go where the dark red tape is).

http://img23.imageshack.us/img23/236...ckup102709.jpg

Re: Firewall Project
 

http://img130.imageshack.us/img130/1...dassembly1.jpg

I've been runnin' the lathe off & on the last few days & got the V-Band clamp flanges done.

http://img33.imageshack.us/img33/720...dassembly2.jpg

Assembled and ready to TIG together

http://img440.imageshack.us/img440/2...dassembly3.jpg

one more check to make sure everything fits like it should.

Re: Firewall Project
 

Had a little time yesterday to work on the "Z". I straightened up a couple places on the firewall so I'd have a straight clean edge to start rebuilding. Then I made one of the two wells the intercooler tubes will pass through. I might use this one or I may try another approach. I'd like the mating surface to be a little smoother than this one. [shrinker sorta' wrinkled it a little]. This is my first attempt at any ''real'' metal shaping so there may be a few trial & error attempts on this deal.


http://img.photobucket.com/albums/v2...rtubewell1.jpg

http://img.photobucket.com/albums/v2...rtubewell2.jpg

Re: Firewall Project
 

I changed up the design of the firewall some. The change affected the shape of the intercooler flange wells. I decided to stamp the parts, I guess mainly because I wanted to give stamping a try.
I cut dies out of 3/4" MDF board & stamped the sheet metal on the press.

http://img.photobucket.com/albums/v2...ubewelldie.jpg

then I rough trimmed the parts.

http://img.photobucket.com/albums/v2...roughparts.jpg

cleaned them up

http://img.photobucket.com/albums/v2...artstrimed.jpg

Welded the front & back halves together

http://img.photobucket.com/albums/v2...cktubewell.jpg

Once I had the tube flanges where I wanted them I welded them together.

http://img.photobucket.com/albums/v2...8/WeldTube.jpg

Re: Firewall Project
 

Sorry I got carried away on the project & by the time I remembered to take pictures I had the outlet tube firewall sheet metal done.
This is the firewall before...

http://img.photobucket.com/albums/v2...Up10-27-09.jpg

and with the intercooler tubes part of the sheet metal in place.

http://img.photobucket.com/albums/v2...talinplace.jpg

http://img.photobucket.com/albums/v2...sheetmetal.jpg

The inlet side is just a simple pie plate deal that will be trimmed & welded into the firewall eventually.
The outlet side was a little more complicated. I didn't want to run the plumbing off to the side (the way it's usually done). I wanted the carb hat facing straight back. Also, the engine is set back about 4" from the stock location. So, the 4" inlet tube has about 3/8" clearance between the windshield and about 1" clearance for the distributor. It's all pretty close but it fits. . The "through the firewall sheet metal'' for the inlet tube ended up looking sorta like shoving the flange through a hefty hefty trash bag. :D

...and here's what it looks like from "the office".

http://img.photobucket.com/albums/v2...indoshield.jpg