There's still a bit to go with the plenum. So next I started on a access door for getting to the W/M jet to change it or maintain it, there is three sizes of jet with the kit and the body that the jet is screwed into has a little bronze filter in it that might need looked at at any time. I got a length of 25x12mm aluminium bar to make a frame, mitred it then vee'ed it out at each join so I could get good penetration with the welder then clamped it to a bit of 6mm plate so it would be flat, and tacked it up, turned it , welded it from the other side. Then back to the first side and filled the gap completely with weld.
This was kinda like the tank job, I was on a mission and I really should have been at work so I was trying to get on. So not a lot of pics.
When all the joins were filled proud, I ground them back flush with the rest of the bar frame. I then cut a lid to go over the frame and marked it out for drilling holes for bolts to seal it. There will be a rubber gasket made to fit the lid/frame. I drilled all the holes out then started tapping them all to M8.
That's not too bad, a bit hefty but it will be easier to seal if it's chunkier.
Next I wanted to have a go at air inlet to the plenum from the turbo. I've looked at this a lot, I've really not been able to decide, inside or outside of the frame rail for the inlet pipe. Inside would be tight and fiddley but really neat if I made a good job of it. Outside would be sticking into my leg. So as I was looking at the access door for the W/M jet I thought, well that sticks out a bit now, another bit of pipe there mightn't hurt? So I'm going to give going outside a bash. Now I did not want to go around the frame rail with a circular section, oval would be better if it does indeed stick into my leg. I was also aware that if you squash a pipe out of round you steadily reduce the actual cross sectional area of the pipe till flat, so simply squashing the pipe wasn't going to do. The pipe coming out of the turbo is 50mm O/D and o have a bit of 32mm O/D pipe that looks like it would do for the sides of the oval. So I'm going from 50mm to 32mm, and I want to do that in the space of 60-70mm and I want it to be as neat and non restrictive as possible. I decided to try folding or shaping plate into a cone. So, make a bender, like this.....
I took the jaws out of the vice and drilled plates for the ends then just zipped a few bits of flatbar together and put a v profile on the other side.
It works a treat! I drew out expanded views of what I wanted to bend up and with lots of lines drawn on for guides, it turned out not bad.
So that was going from 50 to 32mm, I did figure this all out in O/D but it will surely be close to actual, to get the same cross sectional area I need to space off the two sides of the 32mm pipe by 36mm each side, so I made it 40mm because there is more surface area presented to the air at that so a little extra area will give it an easier time, see, I really want as much air in this engine as possible!!!!!
So I cut some bits of plate for the sides and tacked it together then welded it up.
And from the end.
Now I sliced it in half on the saw at an angle turned it around to make a bend and made a couple of slits in it to point it around into the plenum.
And from above.
That's as far as I can get with that for now, I've run out of bands for my power file, I can't clean up the inside of that tube very well without them. So more of that later.
