NZ951

I would suggest you dont use ally. You need a little flexibility in the material. I had to put it in and take it out at least 40 times to different measurements and cutting etc. Becasue the design goes into the header panel cavity, you have to flex it, ally would be well deformed by the end, unless you made it a lot shorter of course. Is the pic I posted of it lying flat enough of a template idea?

NZ951

Cheers. Well the way I see it, you can use stock studs and bolt holes, so you dont dont have to rivot into your body work! I mean how hard does that make working in that area having a huge piece of fibreglass there...

NZ951

Yes I have removed my headlight stopper. I am told its to stop the headlight from tiliting at very high speeds. Well, I cant legally go over 100 on the road here and would not speed at night. So I have no ill effects. I cant recall anyone else saying they have either, and I would think lots have done it. I used an angle grinder. Not the most pretty but effective! I painted the cut afterwards as well... in case it rusted.

84black944

looks good

Crazy Eddie

Looks amazing !!!
I just don't know if I could bring myself to cutting off the headlight stopper...
Frankly, I can't see the headlight moving up even at high speeds because the cone filter is jammed in there behind it ....
Really awesome job ....
You could be like Laust and have every Rennlister buy you design
regards
Ed

NZ951

And now for the data!

Notes:

The ambient temp when testing the "with partition" was 13.5 degrees C. The ambient temp when testing the "without partition" the ambient temp was 18.0 degrees C. So thats a 4.5 degree C difference. So keep that in mind when reading the charts. I have mapped IAT against MAP.

Also note I have 931 vents which I tested to reduce intake temps by a few degrees as well which influence the absolute results but were not changed between tests.

There was a one hour time delay between tests.

All data was collected at 80 degrees engine temp

WITH PARTITION

The typical cruise was consistently +1 degree C over ambient
The MAX degrees C was 28 or 15 over ambient

WITHOUT PARTITION

The typical cruise was consistently +6 degreec C over ambient
The MAX degrees C was 39 or 21 over ambient

So, it works great by the looks of things! Typically there was a 5 - 6 degree C improvement over the MAP range AFTER the ambient temp difference has been accounted for!

testarossa_td

Here is a close approximation to his design.
It was vector created.
However it is based on his picture. Which is not taken directly over the piece and may have some camera lense distortion. I used the frame to the coolant overflow lip for size reference. This template should get you close, I have yet to try it.
Good luck in finding paper large enough
I could not get it to upload so when you open this with Photoshop etc...check the path layer. you will find the vector template.
The height of the back side line should be 22cm. Once you scale it up you should have an accurate enough template to start with.

WARNING. This requires sizing. Printing from this picture will not get you accurate dimensions. You must scale the vector layer.

NZ951

nice job! keep in mind also the rubber gasket thicknesses. The top gasket is about 25mm in gauge and 10mm approx of that is sunk into the fibreglass. Also the "holes" for the intake and water hose have a 5mm approx width seal.

Porsche-O-Phile

The fiberglass probably insulates a helluva lot better than aluminum would anyhow. Nice work man, that's beautiful and works well with everything else you've done.

Crazy Eddie

testarossa_td
Ya killing me !! You must work of the CIA !!!!
Great job guys
Ed

hosrom_951

Good job Andy

testarossa_td

I had a cool name for the template but figured it was not mine to name.

I was going with the T-Rex..something along the lines of a fossilized skull.
Which it kind of resembles.

Pteradon -because it makes your car fly...ok not for me to name.

I took into account a slight insertion depth of the rubber gaskets.
You would cut inside the black lines after it is scaled.(Outside stroke)
Like I said it should get you close enough.
Alright here is the cool, but not practical idea. Use Lexan for the box!

Eyal 951

andrew,
Thats really cool and looks pretty clean! Nice work. and you have numbers too!
~Eyal

NZ951

Feel free to name it

Hopefully people will get some use from your work! Lexan or perspects will be used for the top. Its a one step at a time thing! I tried making a box to start with, but it was too hard with the fllter this size. I dont want to copromise on filter size at all. As it is this one runs out at 440BHP from what I gather.

NZ951

I actually tried at fiest out of 3mm ally. No way was it going to work in a box environment. It may make a good lid (if anything), but not the engine side partition. The ting is, this isa really easy project, I cant recall anyone doing it before? and it gives a very decent gain in lower intake temps (intake temp taken in the IC to TB IC pipe). Its HP for nothing really! Just a little time and maybe if you had to pay retail (20-30 bucks of materials).