Originally Posted by c0ncEpT

Sounds like a solid piece. How much are they getting for one of these compared to an RHS block?

Originally Posted by Broke EF

Well guys, its update time!!! Man, where to start, it's been too long. I guess I can start with the end of last year. The car ran a best of a 9.44 @ 148 with a pretty horrible 1.5 60'. We were slowly creeping up on the launch, and obviously were still decently far away from really pushing it. Sometime in June (too lazy to check) we had trans problems and had to load it up early. The following weekend we pulled the trans and found that the filter had fallen which starved the trans from fluid somewhat. We decided to try and rebuild it ourselves, and also change the rear gear since we were topped out on that 148mph pass.

We eventually built the trans, and changed the rear gear to better suit our needs. We had some trouble with parts while building the trans, which really delayed getting the car back together. Also once it was back together the trans brake was touchy, but more on that later. Unfortunately because of the delays on parts, the trans not working 100%, and other things going on with life (mainly me getting married) we just were not able to get the car back out last year.

At that point we started planning for the new build up. We knew where we needed to make improvements, things we wanted to see done to the car etc. The basic plan at that point consisted of rebuilding the turbo kit, changing the fuel system, changing to a true stand alone, rewiring the car, and a few other smaller things. So now we can move on to the work!


12-2-11
We started work in December before the holidays. Chris had already started ordering parts and material by then. First things first, he decided early on that he wanted to stay with an air to air intercooler, but it was time for an upgrade. He also wanted to make sure that it would be future proof somewhat. After looking at the options, we decided to get a core and make the end tanks ourselves. He went just a little bigger....





I had also bought him a lightweight steering column and quick release from Mid West Chassis, and also a rear firewall from Wolfe racecraft. For some reason I dont have any pics of the rear firewall, but here is the column



Compared to the stock one with a quick release




And installed, dont worry we have a good amount of work left to do in there


We pulled the trans so we could send it out for a proper rebuild.


We also pulled the motor so we could do some work on the engine bay, and make it easier to go through the motor.






12-16-11
All we really did this weekend was strip the engine bay. I decided to make a time lapse video of this, and here it is!
http://youtu.be/lLcR5pQKseQ?hd=1

Chris also pulled the dash and stripped all of the interior wiring as well. No pics of that though.



We had a bit of a break in there during the holidays. I kept doing things at my work though. This next batch is all cell phone pics, so excuse the quality.

I started by drawing up a design for the intercooler end tanks.




Then we made a set up out of some cold rolled sheet metal to make sure the program worked, and practice the bends.

Blank. No hole for the piping since there is no need.


Fits like a glove


This is starting to get BIG


Now that we knew the program was good, it was time to load up the aluminum and make the real parts. Here is the sheet of 1/8" 5052 aluminum loaded up into our PEGA turret punch press.


Here are the two 4" holes for the intercooler piping


And the final two pieces


Next up came forming






And all done!



Next up came cutting the stock 3 bolt flanges off of the truck manifolds, so I could weld on the new stainless steel V-Bands.

All set up in the band saw


And both cut


Here is how the flanges fit before welding


All prepped for welding, had to get that ceramic coating out of the way


AND welded.




1-7-12
That brings us into the new year. During that "between time" that I was doing the above at work, Chris was going through the motor and fixing little things. We pulled the oil pan, re-tapped the holes for the oil feed above the oil filter since one was stripped, cleaned it all up and gave it coat of paint, and also plugged the hole for the oil level sensor. He also replaced the rear cover and rear main seal since we suspected a small leak back there.

Once we were back to work, I got started on welding the intercooler. I was not able to weld the end tanks to the core though since Chris's welder just didn't have the power. I should be doing that at work this week. Here are a couple of pics of my bald head welding though.

First step was to weld the ends of the intercooler as per the instructions that came with the core.


Then I tacked the end tanks to the core, and welded the seams on the end tanks.


Here is the resulting weld, not bad for self taught and my third time welding aluminum


Then we set the intercooler in place to see if it would actually fit


And bumper on, the cooler is what is holding the IC


Just for the heck of it, here are a couple comparison shots with the old IC now that the end tanks are on the new one.





1-7-12
The following weekend we did some work to the motor. Now that the bottom end was all 100%, Chris got to work on the top side. He changed both head gaskets which were in rough shape after that year of abuse I again decided to make a time lapse of us doing the passenger side head gasket.

http://youtu.be/ckny-AfYUgI?hd=1

After the motor was back to 100% we put it back in the car and called it a weekend.