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Author Topic: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"  (Read 135296 times)
Paul Inskeep
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« Reply #125 on: November 21, 2014, 10:42:07 AM »

11-2-14 ends the season. Car did very well and I had a ton of fun.







So the big question. What is going on next year... well stay tuned. Looks like the Merkur won't be dropped as quickly as I had originally intended.
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1990 k20 swapped Gti
1996 328ti
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« Reply #126 on: December 14, 2014, 06:54:55 AM »

Because it relates, here is another water tank I made for another Merkur owner. I hadn't welded aluminum in over 9 months so I was a little nervous about how rusty I may be. Didn't turn out too bad.

This tank has a thick front too so you can tap NPT holes for fittings/barbs or level indicators as necessary. This cut down on the overall cost of the tank and amount of time I spend welding. I was going to produce these, maybe a run of 50 or so, to sell because Merkur tanks are getting hard to find in good shape and the ones you do are expensive. This would be a OE replacement and last forever. I'm not sure if I will still do this however. I have 60 or so dollars in this tank and my time is worth something so unless I sell them for 130-150 I'll just break even. Not sure if anyone, that owns a merkur, would pay that. This one I finished off because someone approached me directly and asked, I had a free morning so why not?

It started by making a jig of the OE tank, since our car doesn't have that location any longer (read wreak). The welding rods are there to map out the general area.



Here is the new bottle and its general location.



Then made a few aluminum tabs



Welded up one on the top and one on the bottom.





Lastly punched a hole in the top and welded a Canton aluminum neck on.







-Paul
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-Paul
1990 k20 swapped Gti
1996 328ti
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« Reply #127 on: December 14, 2014, 11:05:56 AM »

Nice work Paul, looks like I need to get with you when I need some Aluminum welded.

Cheers
Engelbert
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« Reply #128 on: December 21, 2014, 07:30:25 PM »

Not a problem Engelbert, just LMK what you need. I'm local now.

So this weekend I made a little progress on the merkur's face lift that is happening this winter.



40 minutes later...



Then I cut out all the brackets that mounted the old radiator and intercooler setup. Then started test fitting the new setup.



Trying to figure out how the hell I'm going to get the intercooler fed air past this massive radiator... maybe upside down.



-Paul
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« Reply #129 on: December 28, 2014, 09:01:36 AM »

Hope everyone had a good christmas. I got some help this weekend from Pat and we were able to get the nose of the car sorted.

The face lift continues by cutting the end tanks off of the intercooler.





Bars underneath were added for supporting the intercooler and radiator.





Pat then traced out the splitter design on a piece of cardboard.



Here is the potential design. I'm thinking fiber laminated plywood for cheapness.



The idea is to control the air coming into the nose and use more of it for cooling and some downforce. I can't go too low with the splitter like a true race car because it is still street driven, and it overhangs a bit. This is with 5 inches of clearance.



I believe I will be loosing the steel hood with this setup as well and going with a carbon/fiberglass setup because there is no room for a latch. Of course it will need to be home made so we will see how my fiber skills are.
« Last Edit: December 28, 2014, 09:16:04 AM by catapultkid » Logged

-Paul
1990 k20 swapped Gti
1996 328ti
GeneCooley
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« Reply #130 on: December 28, 2014, 12:51:24 PM »

I'm not sure where you are going class-wise (Do I see slicks?) but make sure to read the splitter rules before you get too far into construction.  There are several classes where splitters are allowed, but if your splitter functions as a "wing"--air can pass over top and bottom of the splitter--then you have to put body work behind that portion to stop the over/under flow.
Looks good though, we are looking to add a splitter and spoiler to the Fiat.
Gene Cooley
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« Reply #131 on: December 29, 2014, 06:05:32 AM »

Hey Gene,

The current plans are to run nitto nt-01's (100 treadwear) for street and autox. Along side that I should be in C-Prepared. I know many cars that run with rear wings but I don't see many with large splitters. I took a look at the rules and XP allows aero of all kinds and the CP paragraphs doesn't speak on the manner.

I've been reading into Mark Bardbury's Tbird, Nationals CP car. He has some aero but is notably smaller than what I plan to do.

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-Paul
1990 k20 swapped Gti
1996 328ti
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« Reply #132 on: December 29, 2014, 08:30:48 AM »

The 2015 Rules are available in draft form.  I used the current 2014 rules for section numbers because it's easier to read.  See Section 17 and the CP area in Appendix A.
The T-Bird is most likely maxed out on aero.  The front spoiler/splitter does not protrude beyond the bodywork (bumper cover in this case) and does not extend beyond the front wheel opening.  I missed the maximum width, but I think it's related to body width.  The rear spoiler is approx. 10" blade width measured from the trunk.  There are no endplates or intermediate support plates.  If there was one, the original wing has been removed as required before you can run the spoiler.
See Section 17.2--O & P.
Section 17.10.C has intake restrictor sizes--52mm and a required location.  (This might be for "limited prep" cars but I think it's for all turbo cars.)
There is also more CP info in Appendix A.
All of this is annoying when you are building a car, but it's been developed over the years by CP participants and if you run any SCCA events you want to be legal.  Also, everything we do affects PAX and year end points for everyone in VMSC.
I'm looking forward to seeing it run in its' new configuration.
Gene Cooley
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« Reply #133 on: December 29, 2014, 11:49:38 AM »

So it may get a bit interesting. The other aero portion of the car that I haven't revealed yet (pending on a deal that hasn't been settled) is the addition of a cosworth wing. Below is a image. This really doesn't have much if any bearing on downforce just a nice conversation piece. Until it is in my hands I can't give specifics on dimensions however it does extend more than 10" from the metal but not more than 10" from the orginal OE wing placement as well as it doesn't have more than 10" of a vertical like face. Would this be legal in a prepared category?



VS.



I can see where the splitter needs to be tucked under the car a bit more than I have shown in the cardboard cutout. I can make it flush with the bumper no biggie. It actually doesn't protrude much past the bumper already if at all. The sides just need to be brought in.



Last night I was able to formulate the endtanks to the intercooler. Here is how much room I have to play with.



First attempt



Second attempt



Final result







Now I just need to convert this to aluminum but both my welding helmets have died...
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-Paul
1990 k20 swapped Gti
1996 328ti
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« Reply #134 on: December 29, 2014, 05:59:56 PM »

My first guess is that if the wing isn't original to the car or an option then it's not legal.  If you use the 10" spoiler then you can't keep the wing anyway. 
You need to read through the rules to check bodywork restrictions and get an idea of mechanical restrictions.  It's a pretty open class but it's not "everything's free".  Prepared classes (except XP) are loosely based on Road Race Production class rules rewritten to suit Solo conditions.  They are very specific in some areas and free in others.  It's good to know what they say.
Gene Cooley
PS: It's still a serious looking wing; I'd buy it even if you don't use it.
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« Reply #135 on: January 01, 2015, 06:28:17 PM »

Happy new year. Reviewed the rules. Seems like everything will be doable, I'll post something that puts the rules and what is done to the car in a summary sometime.

Here is the tacked together supports for the radiator and intercooler. I cut off all the old tabs that mounted the various coolers in order to clean everything up. I seriously rushed through the car last year getting it ready so this year I intend to do the things I never got around to doing last year.



Here is where I decided to mount the oil cooler. I had to tuck it slightly in order to get it behind the bumper. I stuck the catch can behind that vertically. All of this will be shielded from the tire before it is all said a done. Still need to find a place for the power steering cooler, I believe it will be on the passenger side as I nicked one of the lines with the sander anyways.



Then moved to a some bumper modifications.



Cut some garden trimming in order to fill the gap between the coming splitter and the bumper.



Here it is mounted.







Now here is the cardboard splitter again. It won't be this low when done. This is at around 3.5"-4" the finial result will be closer to 5" due to being a street car. I wish I could keep it around 3" for track use but it just isn't realistic.



Till next time.
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-Paul
1990 k20 swapped Gti
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« Reply #136 on: January 02, 2015, 01:11:37 PM »

While you're there, you should grind the pointy stubs off those damn rivets in the bumper!  I don't know how many times I've caught my leg on them.
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« Reply #137 on: January 05, 2015, 07:24:49 PM »

While you're there, you should grind the pointy stubs off those damn rivets in the bumper!  I don't know how many times I've caught my leg on them.

Haha yeah I need to take care of those little buggers. I scratched the hell outta myself not that long ago.

Got a little done on the car this weekend.

Passenger side of the intercooler done:



Driver side done. It is very tight trying to get this over the radiator and between the light and supports.



So I bought this "ON SALE!... DIRT CHEAP!..." intercooler piping. That stuff is absolutely miserable to weld, I don't even think it is real aluminum. Not my best work for sure...

Here it is mocked up.



Here it is welded without the blow off valve and IAT sensor added.



I'm surprised but the stock hood closes. It doesn't work with the stock latch and rubs stuff. I've got a idea for it though. Or I'll make one, I've been wanting to do that for some time.

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« Reply #138 on: January 13, 2015, 03:01:57 PM »

Didn't have much time this weekend but I'll add some stuff just to keep up with it.

I started by mounting the new wastegate setup. Ben, SCCA DSP champ, believed in this thing, so for 180 bucks I decided to try it out. You can see the difference in sizing compared to stock.





Mounting and building the downpipe is going to be tighter than I thought.



Next is just some photos of the fab work on the pipes, a tank for Anthony and the intercooler.









Going to get bead blasted next weekend. I like the matte finish.

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« Reply #139 on: January 19, 2015, 06:36:50 PM »

No real updates with weekend, doing other things, spend a few minutes on this. Here is the down pipe. I started it and it wasn't really that bad just need to add a bit more heat wrap/shielding to keep the brake line from baking.





I was able to head to Englebert's garage this weekend and bead blast the boost pipes. Didn't quite match the bead blast I has done on the tank and other pipes but it is better than half of it being shiny. Thanks again Englebert!

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« Reply #140 on: January 19, 2015, 07:47:57 PM »


I was able to head to Englebert's garage this weekend and bead blast the boost pipes. Didn't quite match the bead blast I has done on the tank and other pipes but it is better than half of it being shiny. Thanks again Englebert!



You could try some scotch bright.

The next time we powder coat them, that would look nice.

Cheers
Engelbert
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« Reply #141 on: February 28, 2015, 12:06:52 PM »

Few images of the changes over the last few weeks. It has been cold and the motivation to go to a unheated garage is low.

Some paint, fans and mounting of items.





Turbo feed



Baffles on the inside to force air through the radiator and intercooler.

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-Paul
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« Reply #142 on: March 03, 2015, 06:37:31 PM »


Have you see this vintage MotorWeek segment?
https://www.youtube.com/watch?v=Xw6zjoJUop4

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« Reply #143 on: March 03, 2015, 08:29:06 PM »

That pretty cool Beth, haven't seen it. He even says it right!

Few more additions to the car. Nothing major.

Lower radiator tube made form some tubing I ordered. It runs under the crank pulley nice and tight.



Mocked up some of the exterior stuff it is all in the details now.



Order most of the remaining parts this weekend. So I should be able to get it running in a week or two. Just before the first season autox.
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« Reply #144 on: March 16, 2015, 04:05:13 PM »

Got a little work in late one night/early morning this weekend. Successfully got the car running again with coolant. No leaks and started right up. Just have a downpipe leak issue that needs to be resolved with some sort of gasket.

Car looks better without the body work, shows off all the hard work.





Other than that, downpipe is wrapped and rear extended ARP studs where installed.





Two more weekends.... but the list is still a little long.

New pads
Hood latch of some kind
New tires mounted and balanced
Panels in front of tires to keep splashing at bay
New wastegate install
Fix turbo oil return gasket as it is leaking a little oil
Change oil
Roll fenders
Paint cross bar
Rear differential flush
Put it all back together.
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-Paul
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« Reply #145 on: March 18, 2015, 07:15:32 AM »

What tires and what size are you running this year?
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Paul Inskeep
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« Reply #146 on: March 18, 2015, 11:46:26 AM »

Ricardo: 145/65/14s

Smiley
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« Reply #147 on: March 19, 2015, 01:24:30 PM »

Interesting, don't forget I know your neighbor, I'll ask him to take some pictures of the car. No hiding setups in this club!
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« Reply #148 on: March 20, 2015, 03:45:08 AM »

I've been looking at these hood latches for the hatch seeing that my hood does not close all the way.

http://www.amazon.com/AeroCatch-Plus-Flush-Locking-Latch/dp/B006F441SW
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« Reply #149 on: March 23, 2015, 06:36:18 AM »

Richardo: I guess I'll spill the beans...

Scott: Aero catches are nice, they are by far the cleanest was to do hood pins.

Here are the tires and as you can see they got pretty big...



The challenge was getting them to fit obviously. Thanks to Chris and Amanda being neighbors I get them mounted up in short notice. Thanks again!

They are ballons. 245/50/16 nt-01s



A little beating later with a cheap hammer and dolly set I flared the fenders...



Got a bunch of little things done as well, exhaust leak fixed, hood pin system made etc. Then took it out on its 2015 maiden voyage. Rear still rub pretty bad so I will need to do the same back there.

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-Paul
1990 k20 swapped Gti
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