The manifold rubbed JUST a little bit on the header heat shield. I was so close to making the manifold clear without any modifications. Well, I think it was still a pretty good design job when we were working off of pictures and some rough tape measure measurements.
It’s out of focus, but I wrapped the turbo oil feed line with some DEI exhaust wrap.
You can see where the manifold rubbed on the DEI gold reflective tape stuff. This was my first time using this tape and I rushed it as I had to get the car running, so I didn’t do a good job of putting the tape down tight to the surface. The tape does seem to heat shrink to the surface after some heat was applied from the exhaust heat. Anyway, I used a flathead screwdriver and a mallet to create some clearance between the heat shield and exhaust manifold. The little bit of rub on the left side of the heat shield as from the turbo oil feed line.
Here you can see where I added some extra clearance.
I did some patchwork on the gold foil and I trimmed the back section of the heat shield off to make more clearance to the Turbosmart Comp Gate 40 wastegate. The section I trimmed off had the rearmost fastening location which I could use because the wastegate was too close, so I just cut it all off. I added a rubber edge trim piece to prevent a sharp edge from cutting the wastegate boost reference lines.
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Hey, if it’s not too late or too much of a pain in the ass to remove the oil lines with the heat sleeve on them, you may want to pull them off and get some of the adhesive lined heat shrink to put over the end of the sleeve. Keeps the fiberglass insulation from fraying/getting wet. Awesome build so far, cant wait to see it running!
I have super limited wrench time right now, so it has to go 100% to getting this car done. Good advice though!
Such a cool and detailed project. The packaging does not look fun at all. One has to wonder if a centrifugal supercharger would make more sense? e.g. something procharger or rotrex based. good high RPM power, less heat issues in engine bay, maybe better overall packaging?
Have you read the first 32 parts before commenting on this article, part 33?
A supercharger setup won’t do 320 torque crank at 3250rpm 🙂 I think my setup will do it on 91 octane. That’s the target at least! Double what a stock S2k will do and hold that torque flat to redline for 500hp crank at 8200rpm. I want double the mid-range torque to make the car more fun and useable on the street.
I am just so glad to see you get this far! Kudos! Can’t wait for a dyno pull, though!
Man….. FMIC for the win buddy, I’d tear all that out and start again
Have you read the first 32 parts before commenting on this article, part 33?
If it were a track car, air to air all the way. I’m targeting max response for the street, so minimizing the IC plumbing length along with keeping the intake air temps cool even from a stop. Sitting at a stop, I can have the SPAL fan going (A/C turned on) to keep the coolant cool and basically keep the IATs at ambient even leaving from a stop. Even without the SPAL fan running, there is a lot more thermal mass with the coolant in the IC system to reduce heat soak.
My goodness that’s a lot of careful packaging. Look forwards to when you can see what it’s all capable of!
Can’t quite tell from the picture of your I/C water pump but it doesn’t look rubber mounted, if you had some way to isolate it from the chassis the noise might be significantly reduced.
There’s a better picture in the link below. It’s a rubber mount/sleeve the pump slides into. Once the engine is running, you cannot hear the pump from inside the car. Outside the car, you really have to listen for it and stand near the corner where the pump is mounted to notice it. So no more worries on pump noise! I was over-thinking things a bit there.
https://motoiq.com/project-s2000-part-30-cooling-upgrades-and-packaging-improvements/5/
I had a W2A intercooler whose core loved back by the firewall. Silly me never ran a reservoir and that thing got HOT but wasn’t prone to puking. Yours is a much better setup, and I probably read it 20 episodes ago, but do you have a hood vent or something to keep the engine heat from dumping into the core? Being in front of the heat source helps I’m sure
No more vented track hood in order to stay low key. I have the air deflector underneath the intercooler core to shield it from the warm air from the radiator. The coolant pump runs 100% of the time for the IC so it’ll cool the core anytime I’m not boosting. At the situation of sitting at a stop light, I can turn on the A/C to run the fans including the fan on the heat exchanger for the IC system. I’ve tested it where if I turn on the A/C and run the heater at full blast, it’ll pull the engine coolant temp down pretty quickly. Even below the thermostat setting for a bit before the thermostat adjusts. Though in everyday driving, that won’t be necessary as I’ll be traction limited in first gear anyway.