Shoptalkforums.com

Since there's not much in the way of projects going on I thought I'd share a slow one I've been working on .
I'm in the slow process of building a 2.6lt for a Ghia ,After issues with uneven cooling and the price of 911 fan/alternators in Australia I decided to go with a Cali style cooling system with a difference . Getting the air to blow evenly between the cylinders .
If I was in the States I'd just get a DTM but because of freight and currency it would end up over $2000AUD . So I'm having a go at moulding my own design shroud that is centre mounted . Progress has been slow but it's finally starting to take shape . http://www.shoptalkforums.com/download/ ... w&id=18246
the cylinder covers were made by using the original tin cylinders #1 and #3 as a plug , then joining the moulds and making the duct in the top , it's the same dimension as a type 4 1/2 side . the mould makes both sides .
I made up an Alternator /Ac compressor bracket , the plan is to run a single serpentine belt .Then started cutting and glueing pine blocks together to get the shape I'm chasing to make a plug for the shroud .
http://www.shoptalkforums.com/download/ ... w&id=18252
http://www.shoptalkforums.com/download/ ... w&id=18253
I'm getting to the stage of sealing the pine then using high build primer and rubbing back to remove any high /low spots . Hopefully I'll get a prototype moulded off the plug for flow testing in the next few weeks . I've a fan mounted to a 3000 watt brushless motor from an RC aircraft (another hobby) that I'll use to check flow .

Wow, sure looks cool! Really nice work. Many will be interested in your results. DTM and Cali style have led the charge for many years.

doc

Looks great , a lot of time and effort went into this. Mike McCarthy

Very interesting! What, if anything will be inside your design; airflow guide wise or will it be just open? I am impressed for sure.

Lee

Wow,very nice cant wait to see it finished. Man you are handy with wood. This is what this forum is all about sharing ideas.

Keep us posted.

Thanks for the compliments guys. Joe I started making balsawood model planes when I was a kid back when all you got in the box was a plan and a pack of balsa .
Lee the plan is to make an internal wall that runs down to the 1/2 side , then test it with strands of wool to see if it will need guide vanes to get airflow to the inner area of the ducts . I've an micro pitot tube to measure air speed from a fixed wing drone that I can use to check airspeed after I'm happy with the wool strand method .
Funny how sometimes you stumble on things by accident . if you want to make a velocity ring for a type 1 fan , grab a fan and some fibreglass and lay up a bit of glass around the outside of the intake part of the fan , it gives a lovely radius the correct diameter . covering the fan in packing tape makes an easy mould release .

As you may know I have been doing industrial designs for the elevator industry for over 40 years and did may modifications to the original Twin Towers World Trade Center of 9/11. The elevators were at the time the fastest in the world at 1600 fpm. Elevators ride on rails like a train and also do there counterweights. In high winds the building swayed feet in each direction, which can cause the elevator or counter weights to derail. 3 cup Anemometers were used to tell the computers to slow the elevators to a safe 1000 fpm. Problem was the in NYC snow or ice storms also have winds and the Cups freeze. I was the guy that designed Pitot tubes into the system. No moving parts.

Wow Joe that that's a great achievement and slice of history, very sad that the Word Trade Centre is now so famous because of that despicable act .
On the subject of Pitot tubes , sadly good friends of mine were badly injured on an Qantas Airbus that went into a rapid decent because of a frozen pitot , before Airbus rectified the heating issue . One of the friends will always have back and leg issues but are thankful to be alive .

Yipes!!!! Well I guess they fail to, but I can't imagine how long those 3 spinning cups would have latested on a jet doing 500mph . Pitot tubes win longevity contest. Ha

Slowly getting there with the shroud after a break over Christmas /New years . I had friends staying for a few weeks and didn't think they would like the lovely aroma of polyester resin . It's also the hottest time of the year ,39c (102F) forecast for today .so I can only work early mornings or the resin starts curing before I can finish laying down the glass.
. http://www.shoptalkforums.com/download/ ... w&id=18503

Because of the complex shape a split mould is needed , one side layer up first , the blue colour is PVA release film,magic stuff.
http://www.shoptalkforums.com/download/ ... w&id=18501

both sides of the mould , hopefully have a shroud to start testing by next weekend .

There was an story in a local Aussie mag about a rallycross bug with a type 4 in the 70/80s in Australia , it is most likely the one Joe has mentioned a few times .
http://www.shoptalkforums.com/download/ ... w&id=18506

http://www.shoptalkforums.com/download/ ... w&id=18505
http://www.shoptalkforums.com/download/ ... w&id=18504

Wow.

Nice work mate, good to see another Aussie thinking outside the box. The system may only need minimal directional vanes.
Keep it up, been a long time since i've been on here and it's good to see the forum getting revived.

Thanks Benito , Hopefully just a vane each side to direct the flow . I stuffed up a bit and didn't allow enough fan clearance with the thickness of the glass . So a bit more work before I can start testing . Did you ever use those Deutz cylinders ? John Alder at Volksengineering is chasing some used ones . http://www.shoptalkforums.com/download/ ... w&id=18568

Stick a pre-doghouse fan in it for testing.

It should still work ~the same, plus its useful info as some folks swap fans out between summer and winter.
If it still provides good, uniform cooling that literally saves a few HP at high RPM.

I've an early fan but it was hitting as well .
I've cut down the lip around the fan so the fan protrudes out of the shroud , I'm going to pack up the fan with some tape to give a bit more clearance and glass over it, should work . I've a fibreglass velocity ring that I want to use so will need the shroud to go out past the intake lip of the fan . If that makes any sense .