Another money pit

[rtj]

Finally slowed down on my home improvement projects to get my Camaro running. It has sat for 5 years.

Everything was done to support 1200 hp, but the engine is just a beat/abused 502. Timing is locked and I need to mess with the 7531 box some more. I've got to pull the rad and install the crank support and intercooler.

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The original plan was use the 502 to learn blower basics, but who knows where this will go. People say a 502/F2 can do over 800hp (with cam, et cetera ).

[rtj]

Not much left to do now. Modified the crank support for use with a procharger.

[Red77]

That's a serious piece of hardware! Better than snapping off the snout though.

[rtj]

Apparently you can do considerable damage to the crank and main bearings without one. Especially with cog belts.

[rtj]

I got to the point on the house where any more improvements will be diminishing returns, so I’m working on the cars more.




Made this in order to pin the balancer properly. The gen v has a large key, but I was afraid 1 key wasn’t enough.

Got the mandrel in at +/- 0.001”. Took a lot of fitting/machining to get the mandrel right. Then more fitting to get the bearing on with no bind.




Did some polishing and made a blower strut rod support.




My amazon 50$ valve covers. Need to drill and weld in 16an fittings on both for vent lines. I’m currently notching the other for blower clearance. Glad I’m not hacking up $300 valve covers.

[rtj]

Forgot one photo, drove it out of the shop last summer and washed it off.

[rtj]

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I might try this. They are sending me a new tig. Long story.

Otherwise, I’d go with a Chiseled, but it’s big.

Sorry can’t embed yet, here’s the mock-up.

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[bobs77vet]

nice looks like a fun project.....i am kind of getting in the mood again...

[rtj]

Originally Posted by bobs77vet

nice looks like a fun project.....i am kind of getting in the mood again...

Yeah, please do. We need another good long project thread! I enjoyed watching the last car being resurrected.

I wish I had more to post, but I’ve been on a welder repair odyssey! My new Precision 225 arrives today. Keeping fingers crossed. Way more machine than I need, but in the end may be lower cost than the entry level machines.

[rtj]

They sell a core that is 4” less in width than what Chiseled Perf. sells. I may go this route if my alum welding skills progress.

Vibrant Perf. Horizontal Flow Intercooler Core
HP Rating: 1300
Core Width: 18"
Core Height: 12"
Core Thickness: 6"

$369

[bobs77vet]

I have wanted to pick up a spool gun for my hobart handler ...so i can weld aluminum but i have not had the need yet.

[rtj]

Spent most of the summer on home improvements, getting back on the cars.

Some photos.

Got the precision tig 225, definitely a far better welder than anything I’ve tried. It will be me that holds it back.



My first alum project was the valve covers. I think I made every rookie mistake possible, except melting them down or blowing big holes. Fittings are welded on the inside.



Some lessons learned:

1) buy a new can of acetone
2) scotch brite and acetone wipe all your welding rod
3) running shoes are better than workboots on the pedal

Probably more, but those were big.

Am making puke tanks now, so decided to practice! A few more and I’ll be good to go.

[rtj]

Bead roller nearly ready.




Frozen boost intercooler piping is pretty reasonable. How much longer with all these tarrifs is anyone’s guess.



I may try to make up some lightweight side pipe mufflers with similar material after the Camaro is running.

[OZgreen69]

for alloy welding? lot of practice, being steady and some swearing involved !!
Being steady is my problem

[rtj]

Originally Posted by OZgreen69

for alloy welding? lot of practice, being steady and some swearing involved !!
Being steady is my problem

Yeah, I watched a lot of how-to vids and “propping” seems to be the way to go. It took forever to get all my contamination sources fixed. I guess I had used oily rags with my old acetone container and it was no good for cleaning alum.

Definitely hoping to improve, that opens up the possibility of projects like your alum cooling ducts.

[Red77]

I never got good at the aluminum. The slightest bit of contamination will build an oxide layer that takes more heat to melt than the aluminum below, then the next thing you know, you have a blowout. I need to practice again. I agree on shoes over boots, anything you can do to get better feel and control when you are learning is a step in the right direction.

[rtj]

Originally Posted by Red77

The slightest bit of contamination will build an oxide layer that takes more heat to melt than the aluminum below, then the next thing you know, you have a blowout.

Yes, it took me for ever to realize my rods were a bit oily and had an oxide layer. They looked clean and shiny.

I found cutting scotch brite pads into 1” squares is a good way to always have a clean pad.

About half done on my tank now.

[rtj]

Tank done, except brackets.






Next up, belt guard or intercooler piping. I’ve decided on the 1300hp core, but want more practice.

[OZgreen69]

Looks really good

[rtj]

Thanks, still learning.

Got some tubing bead rolled. And, will start welding it up. Ordering intercooler now I’m feeling more confident. Will post some pics soon.

[rtj]

Small progress, brace and hat installed.



Made steel bulkheads for the rad support 4.5” id. Also, made an alum stand off for the BOV. I tacked it up then chickened out welding it ( don’t want to melt it down!). Need a few more days of practice doing 1/4” t-joints to get confident in my settings and skill.



Made an adjustable fence for my HF bead roller. One sided fence only means you can only crank one way while working the metal. Intercooler inlets and blower 180. I may make billet intercooler inlets, not sure.




I have to learn to plan better, switching back and forth with the vice and rotary table gets old fast.

[rtj]

I’m starting to think of this car as a barn find.

Thanks Kevin, the swag stand is working great for intercooler tubing with a few mods. 3” angle iron would have been better for making the table bigger, but 2” is working. The two sides on the slide keep the tubing from rolling when cutting and since they are 1/2 the diameter flipping 180 deg is easy.





Getting some better welds on these pie cut 90’s. They need to go from vert 90 deg to horz 90 to get through the rad support, so two transition pieces left to make.

This 180 needs to be split and widened an inch or two.

[BBShark]

Looks like the HF bead roller worked pretty well. Nice job on the turbo ducting.

[rtj]

The bead roller works great once you do the YouTube mods (reinforced base).

This hf bandsaw is great. I’m tempted to grab another on sale for hand held. There is bi___hing on line about the hf blades, but at 7$ each, I can’t complain. Can cut a lot of alum, steel wears them out a lot faster. Swag should add the premade table extensions (angles). It really increases table size easily.


I forgot to mention, holding the pie cuts together with clamps is impossible, but safety wire works great until you get your tacks on.


One other thing I learned after getting 3 damaged intercooler cores over a period of 2 months, maybe they should package these. All three were shipped in a cardboard box with no packing. They finally refunded my money, I guess it was easier than having the shipping dept do their job. I will order directly from vibrant and request packing.

[rtj]

Summit racing has a pick-up option and has a store an hour or two away. So that is how I’ll get an undamaged core.

[rtj]

I found even crummy welds don’t look too bad after running them over the buffing wheel. Can’t believe how light this tube is when done.

I got a nice tubing bender and started a blower belt guard using 1/2” chrome moly tubing. First bend is complete.

[BBShark]

Originally Posted by rtj

I found even crummy welds don’t look too bad after running them over the buffing wheel. Can’t believe how light this tube is when done.

I got a nice tubing bender and started a blower belt guard using 1/2” chrome moly tubing. First bend is complete.

Very nice. That is one of those things that is way harder than it looks.

[rtj]

Thanks BBShark, it looked pretty bad until I polished it. The little bandsaw and Lincoln welder really helped. Plus, I finally started to get the feel for aluminum. I behaves so much different than steel. Still not stacking dimes, but hopefully they’ll pass my home-brewed pressure test next summer.


Next project, ready for tacking. The mill-drill and bender were key. Giving my eyes a rest before doing more aluminum tubing.

[69427]

Originally Posted by rtj

I found even crummy welds don’t look too bad after running them over the buffing wheel. Can’t believe how light this tube is when done.

........................

Looking good.

Most of my '69 exhaust is aluminum tubing. Four inch elbows were too damn pricey for my taste, so I did a similar pie cut thing. Works just fine.

Keep up the good work.

[rtj]

[quote=69427;134702]

Originally Posted by rtj

Looking good.

Most of my '69 exhaust is aluminum tubing. Four inch elbows were too damn pricey for my taste, so I did a similar pie cut thing. Works just fine.

Keep up the good work.

Thanks, I keep thinking about alum sidepipe mufflers. Yes, pie cuts are pretty good once you try them. It has me thinking of custom headers.

Blower belt guard progress. 1/2 inch chrome moly tubing welded up and this think is solid.