Hot Rods Cheatin' The Reaper

More flange......
The turbo exhaust flanges started out as a sheet of 10mm (3/8") steel plate which had holes strategically drilled in it:

17021677_664272940426081_5796235480056569434_n by Legendlives posted Mar 4, 2017 at 2:09 PM

These were then cut out and shaped:

17103293_664272980426077_2533474195045615259_n by Legendlives posted Mar 4, 2017 at 2:09 PM

The internal bore was tapered to match the outlet size exactly:

17103293_664272980426077_2533474195045615259_n by Legendlives posted Mar 4, 2017 at 2:09 PM

And then 'V' band clamp fittings welded on the outside:

17103453_664272990426076_3394200584790870779_n by Legendlives posted Mar 4, 2017 at 2:09 PM

I also seam welded around the inside. Just because!

15590330_664272960426079_8918902891509994770_n by Legendlives posted Mar 4, 2017 at 2:09 PM

I know there are those on here who disapprove of my choice of power plant and power adders, but I am doing exactly what real rodders have done since day 1 - making mis-matched parts work together without spending shed-loads of money. To date I have hundreds of hours, but less than $4000NZ total invested in the project.
Also, engine aside, racers have been using turbos for decades so although they are perceived as a 'modern' power adder they have merely become more popular in recent years.

 

Back on the rollcage, I've at last managed to fix the upper seat belt/harness mount plate in place.

DSC00544 by Legendlives posted Mar 7, 2017 at 11:48 PM

It's made from 5mm steel plate, suitably drilled and chamfered, and with captive threads for the 4 mounts. Each side is fully seam welded to the underside of the tube where it's important and the span between is stitch-welded.
Left hand:

DSC00549 by Legendlives posted Mar 7, 2017 at 11:48 PM

And right-hand:

DSC00546 by Legendlives posted Mar 7, 2017 at 11:48 PM

Each side has these triangular gussets underneath which are fully perimeter welded:

DSC00548 by Legendlives posted Mar 7, 2017 at 11:48 PM

The rollcage now looks like this:

DSC00550 by Legendlives posted Mar 7, 2017 at 11:48 PM

As there are so many joints on the cage I've been red-oxide painting each one as it's fully welded.

 

Just had a brilliant weekend. Just me, the car, and my welder.
I've now finish-welded all of the rollcage joints, and all of the main chassis joints (including all of the lower seatbelt/harness mounts, seat crossmembers, shifter crossmember, transmission rear mount, handbrake mount and a few others!)
I even managed to make and fit this crossmember at the rear of the chassis ladder which will have the rear radius rod mounts welded to it:

IMG_1141 by Legendlives posted Mar 11, 2017 at 10:52 PM

IMG_1142 by Legendlives posted Mar 11, 2017 at 10:52 PM

You can't quite see in the photo's, but this tube is curved down in the centre to miss the drive-shaft.

Next project(s) are the body mounts. These are already designed and will be made this week, then (hopefully) fitted next weekend.

 

Outstanding job my friend.
Hopefully you won't ever need to test any of that safety stuff or weld integrity.
I'd run that engine that shouldn't be mentioned here too! And boost the hell out of it.

I need to get in at the top of the page or I can't

 

That´s a crazy amount of engineering you put into that frame and cage.... just beautiful!

 

Manifold part one:
It has always been my intention to run a carb on the engine, either N/A or (as it will be now) Blow-through, so it's about time I sorted a manifold out.
Starting with the original injection manifold (which looked like this once the plenum box was unbolted),

IMG_1310 by Legendlives posted Jun 12, 2017 at 8:12 PM

I gave it to a friend of mine who has a mill, and after a few days he returned with this:

IMG_1365 by Legendlives posted Jun 12, 2017 at 8:12 PM

IMG_1364 by Legendlives posted Jun 12, 2017 at 8:12 PM

Which I then proceeded to hack more lumps off:

IMG_1371 by Legendlives posted Jun 12, 2017 at 8:12 PM

A visit to another friend with an industrial guillotine and bender produced this panel:

IMG_1372 by Legendlives posted Jun 12, 2017 at 8:12 PM

IMG_1373 by Legendlives posted Jun 12, 2017 at 8:12 PM

Which I then got excited about and decided to fit curved ends to. These were cut from alloy tube and seam welded in and out:

IMG_1374 by Legendlives posted Jun 12, 2017 at 8:12 PM

IMG_1375 by Legendlives posted Jun 12, 2017 at 8:12 PM

To mount the carb I found this spacer cheap, which I then cut about a bit:

590032493 by Legendlives posted Jun 12, 2017 at 8:12 PM

IMG_1353 by Legendlives posted Jun 12, 2017 at 8:12 PM

As it happens I cut it about even more before welding it on, but here it is rested in place on the smoothed plenum:

IMG_1378 by Legendlives posted Jun 12, 2017 at 8:16 PM

After welding on the carb plate I thought I'd better trial fit it before getting all weldy with it.

IMG_1382 by Legendlives posted Jun 12, 2017 at 8:16 PM

IMG_1381 by Legendlives posted Jun 12, 2017 at 8:16 PM

Still a way to go, but I'm quite happy with it so far.
Stay tuned for part 2!