layout2.JPG
132 hits | 55.14 KB | Posted: 10/24/15
Laying out the intake flange side of things. This is an idealized version of the ports. The intake will need minor work to match. I'm keeping the divider all the way to the throttle body to keep the airflow to each side even.
(Posted in: Carb intake to throttle body elbow adapter)

on engine rough holes.JPG
150 hits | 68.18 KB | Posted: 10/24/15
Starting to cut out the ports. Cut out a pair of circles with a hole saw to get a bunch of material out at once. The adapter fits the studs like a glove. I swapped out these old studs for ARP versions later.
(Posted in: Carb intake to throttle body elbow adapter)

Raw material.JPG
142 hits | 54.14 KB | Posted: 10/24/15
One block of 1" x 6" 6061 aluminum. Raw material. There's an adapter in there somewhere.
(Posted in: Carb intake to throttle body elbow adapter)

rough holes.JPG
141 hits | 75.09 KB | Posted: 10/24/15
Got the straight through section of the ports roughed out. Now to grind the angles in to match both ports. I used a aluminum-specific carbide burr for this.
(Posted in: Carb intake to throttle body elbow adapter)

roughed in1.JPG
140 hits | 42.73 KB | Posted: 10/24/15
The ports are a bit rough but at this point it's a functional piece. Everything else is polish.
(Posted in: Carb intake to throttle body elbow adapter)

roughed in2.JPG
143 hits | 43.05 KB | Posted: 10/24/15
Die grinder with carbide bit got the ports roughed in pretty well. Need to do finishing work on the outer profile and sand the ports smooth. That takes most of the time.
(Posted in: Carb intake to throttle body elbow adapter)

router1.JPG
150 hits | 74.5 KB | Posted: 10/24/15
Used my router with a plunge cuttting straight bit to rough in the first 1/8" of each side. Just easier and faster than the die grinder.
(Posted in: Carb intake to throttle body elbow adapter)

router2.JPG
153 hits | 77.9 KB | Posted: 10/24/15
More router work on this side.
(Posted in: Carb intake to throttle body elbow adapter)

floor1.JPG
130 hits | 65.93 KB | Posted: 3/8/16
Summit Racing sport seats sitting on modified stock seat brackets. I thought I took more pictures of this.
(Posted in: Floor pans and carpet)

floor8.jpg
127 hits | 64.44 KB | Posted: 3/9/16
Front mount for the center console and the tower for the shifter boot. Made it flanged for rivets to match a lot of OEM designs. It got riveted down over a fat bead of seam sealer after everything was painted. It shouldn't rust.
(Posted in: Floor pans and carpet)

floor4.jpg
123 hits | 68.55 KB | Posted: 3/9/16
Rust repair on the floor pans. Pics of the rust and cutting sheet metal won't load for some reason. Just spot welded here.
(Posted in: Floor pans and carpet)

floor5.jpg
118 hits | 65.04 KB | Posted: 3/9/16
Fully welded patch panel. I don't care about grinding the welds since it will be all under the carpet and insulation anyway.
(Posted in: Floor pans and carpet)

floor7.jpg
122 hits | 63.83 KB | Posted: 3/9/16
Passenger side panel fixed. Any remaining rust got hosed down with rust converter, then rusty metal primer, then rustoleum. I don't want to be back here again. The bottom gets the same treatment plus undercoating at some point.
(Posted in: Floor pans and carpet)

2222.JPG
160 hits | 70.65 KB | Posted: 5/20/16
Rotten floor pan. Need to fix this.
(Posted in: Floor pans and carpet)

3333.JPG
151 hits | 46.32 KB | Posted: 5/20/16
Bad on on side, new on the other. Just cut out of 20-gauge sheet.
(Posted in: Floor pans and carpet)

6666.JPG
144 hits | 44.73 KB | Posted: 5/20/16
New and old. Takes a lot of trimming to get a good butt weld.
(Posted in: Floor pans and carpet)

IMG_2563.JPG
102 hits | 46.84 KB | Posted: 3/10/16
Cardboard rough draft. Just checking heights and such.
(Posted in: Center console )

IMG_2572.JPG
115 hits | 30.52 KB | Posted: 3/10/16
Drawing out the second version.
(Posted in: Center console )

IMG_2573.JPG
105 hits | 38.15 KB | Posted: 3/10/16
More drawings. Better to find problems on paper then later.
(Posted in: Center console )

IMG_2574.JPG
102 hits | 32.81 KB | Posted: 3/10/16
These are all to scale. Some are 1:1.
(Posted in: Center console )

IMG_2598.JPG
97 hits | 53.3 KB | Posted: 3/10/16
Prototype. Much easier to mock up in styrofoam than in MDF.
(Posted in: Center console )

IMG_2599.JPG
94 hits | 51.88 KB | Posted: 3/10/16
Storage in the arm rest, cup holders, shifter, pull out cup holders for the rear, and temp/volt gauges up front. Oh, and 12 V power and USB power.
(Posted in: Center console )

IMG_2626.JPG
111 hits | 54.56 KB | Posted: 3/10/16
Working on the core.
(Posted in: Center console )

IMG_2627.JPG
114 hits | 59.35 KB | Posted: 3/10/16
Mostly roughed in. Lots of finish work to do though.
(Posted in: Center console )

IMG_2630.JPG
94 hits | 73.37 KB | Posted: 3/10/16
Holes for cup holders. These are 3 5/8 inch and I bought a 3 5/8 inch hole saw. They are a light interference fit. Perfect.
(Posted in: Center console )

IMG_2632.JPG
113 hits | 58.52 KB | Posted: 3/10/16
They are offset to one side to clear my arm angle to the shifter.
(Posted in: Center console )

IMG_2633.JPG
120 hits | 70.04 KB | Posted: 3/10/16
Mocked up with shifter boot and trim ring. I stitched that boot too.
(Posted in: Center console )

IMG_2680.JPG
121 hits | 41.76 KB | Posted: 3/10/16
Beginning to cover it in vinyl. I made the sides removable and bolted from inside so it would hide the seam.
(Posted in: Center console )

IMG_2681.JPG
107 hits | 59.92 KB | Posted: 3/10/16
Slowly working the vinyl down and around. Patience.
(Posted in: Center console )

IMG_2683.JPG
97 hits | 54.68 KB | Posted: 3/10/16
Covered in vinyl! Still need to make the pull out cup holders but coming along.
(Posted in: Center console )

IMG_2688.JPG
115 hits | 36.5 KB | Posted: 3/10/16
Checking the fit to the rear carpet. Perfect.
(Posted in: Center console )

IMG_2689.JPG
100 hits | 48.7 KB | Posted: 3/10/16
Pull out cup holders for the rear passengers. Not too shabby.
(Posted in: Center console )

IMG_2690.JPG
103 hits | 30.89 KB | Posted: 3/10/16
Nice aluminum drawer pull. I like.
(Posted in: Center console )

IMG_2875.JPG
167 hits | 73.81 KB | Posted: 5/20/16
Console mock up with lid and drawer.
(Posted in: Center console )

IMG_2885 (Edited).JPG
163 hits | 59.46 KB | Posted: 5/20/16
Trim ring and gauges set in place.
(Posted in: Center console )

IMG_2901.JPG
165 hits | 51.86 KB | Posted: 5/20/16
Drawer and lid installed all open.
(Posted in: Center console )

IMG_2902.JPG
138 hits | 50.2 KB | Posted: 5/20/16
Drawer and lid installed all closed.
(Posted in: Center console )

IMG_2470.JPG
188 hits | 58.2 KB | Posted: 3/10/16
Display for the Tech Edge wide band O2.
(Posted in: Megasquirt fuel injection)

IMG_2757.JPG
141 hits | 75.5 KB | Posted: 3/10/16
Big ol pile of fuel injection parts. This isn't all of it either. Takes a bunch of little bits to do things.
(Posted in: Megasquirt fuel injection)

IMG_2760.JPG
152 hits | 59.91 KB | Posted: 3/10/16
Assembling the Megasquirt. Lots of soldering.
(Posted in: Megasquirt fuel injection)

IMG_2761.JPG
155 hits | 84.85 KB | Posted: 3/10/16
Mostly done. Had a bit of trouble getting the laptop to talk to the ECM but I got it figured out.
(Posted in: Megasquirt fuel injection)

IMG_2824.JPG
173 hits | 72.17 KB | Posted: 3/10/16
Made a bracket to hold the intake flat for boring the injector holes. Simple 45 degree plate bolts to the intake flange and bolts to the drill press.
(Posted in: Megasquirt fuel injection)

IMG_2825.JPG
164 hits | 62.52 KB | Posted: 3/10/16
Welded lug supports the intake port. I bored a hole under this so the bit wouldn't ride down the flange and screw up the hole.
(Posted in: Megasquirt fuel injection)

IMG_2826.JPG
170 hits | 74.07 KB | Posted: 3/10/16
Boring the injector bung holes. I used normal water to lubricate the bit so there wasn't any oil to soak into the aluminum and contaminate the weld. I had to constantly spray water but it worked fine. I already spent a lot of time boiling this intake...
(Posted in: Megasquirt fuel injection)

IMG_2827.JPG
173 hits | 68.23 KB | Posted: 3/10/16
Boring another hole. Setup worked just fine.
(Posted in: Megasquirt fuel injection)