Oil Cooler Duct/Air Guide

[Mɐʇʇ]

Here you go. This is one of the most important bits and I did remember to take a photo. If you make a pair of these, you'll be a good way there.
These are the angled end caps of the air duct.

There's a 90 degree bend along the horizontal 93 and 70.
I made them out of 1.5mm NS4 - so the green number (67) is where I placed the 90 degree bends to give me a 70mm overall height after bending.
And with a 20 mm return for riveting, this meant the overall height of the bit was 107mm.

The dotted green lines are "trim after" to fit the top and bottom sections of the duct.

I've also attached some pics of the parts - with a bit of eyeballing, you should be able to get fairly close.

[airtite]

awesome, would this carbon board work instaed of the ns4?

https://www.bidorbuy.co.za/item/4349564 ... gJmn_D_BwE

[Ajc]

As long as you don’t need to put any bends in it it should be fine

[Mɐʇʇ]

If I'd done carbon, I was gonna use 2 or 3mm Ali angle to do the joins (cos I have some).

1mm carbon might be a bit flimsy, it’s much more brittle than ali. It needs a bit of thickness (usually with a core) to give it strength.

[IchBautAuto]

Personally Id say that Polyprop or similar like the inner guards tub is the perfect material for the duct followed by Alu. CF is a huge overkill and far from the best choice of material. The only reason I wouldn't go Alu as a first choice for me is stone chips and flecks of shiny showing. My front end is blacked out so it'd look out of place.

[Ajc]

Kevlar would be my composite of choice , not as brittle Matt said , but flax would be another good shout , however I’m not sure if you can buy in sheet form .

[Ajc]

Him pretty sure than the original guide is pp anyway isnt it so to build another out of it would be a little pointless, plus it doesn’t have the cool factor

[IchBautAuto]

Only be pointless for non practical reasons. 15 year life, functional, perhaps a slightly different design. The cool factor is over rated. A few years on and you think, what was I thinking? Everyone should live their life and if cool is the thing, all good but it isn't for everyone.

[Mɐʇʇ]

I did NS4 because it's a decent enough material that's easy enough to fabricate stuff out of and I knew it wouldn't be.completely <beep>. SC1 would be ok, but it's softer.

I have some lovely 3mm carbon in stock - but functionally it would have been the same and aesthetically, well, you basically can't see it anyway. And I think it'd have been a bit more effort.

If you really wanted, brown paper and epoxy resin. Or chopped strand GRP and polyester.

Easy to overthink it all. Make it out of whatever takes your fancy, it's a non structural component.

[Ajc]

Ha ha never underestimate the cool factor , it instantly adds 50bhp ya know , I get what you’re saying but for me pp is something I repair day in day out and it has it’s downfalls as well as it’s perks . That said I think most materials will have . Ali isn’t a bad shout as Matt has done , its forgiving too work with and will stand up to the abuse of road crap and a good jet wash without damaging it

[Mɐʇʇ]

I hear you - and I don't underestimate.

I spent - honestly - thousands and thousands - on building an EFI 8-stack injection system that looks like it's old school mechanical. Because it was cool.
I could have had the same performance from a turn key EFI plenum injection manifold. But it isn't as cool (in my eyes - and that's all that matters).

Tennis Ball Launcher:

Sometimes it's good to do stuff "just because".

My car is also all black (in & out) with the aluminium interior trim - so aluminium is well in keeping with it.

Anyway, I think I need to give my duct a tweak - if I can be arsed - so bumper might be coming off again. If I do, I'll take some proper measurements and draw out a cad diagram.

[IchBautAuto]

.........................
Sometimes it's good to do stuff "just because".
...................................

That's what it's all about. As you said, doesn't mean that it is either an economical solution or a performance improvement, just because. Love the stacks, had mechanical injection in the days and damn glad it's gone. Reminds me of the day when I had a 750 desmo. Supplied with open intakes and the opinion of a well respected journo was that quality engineering didn't need air filters.

[Mɐʇʇ]

Yeah, I don't think I could have stomached mechanical.

It's running a self built megasquirt with wasted spark (no dizzy) and hybrid "ITB" load algorithm - so it uses the map and TPS at low load, but with the stacks, you lose all vacuum pretty quickly so it switches to Alpha-N. Runs well across the range.

[IchBautAuto]

You know the old joke about making a small fortune? boats and RS6's, you must have succeeded beyond your wildest dreams.

How many hours would you run that V8 in a year? Looks like fun.

[Mɐʇʇ]

If that were true, I certainly wouldn't be out late at night in the garage, night after night, bolting old cars and other bits of crap back together.
My approach has always been to make things I want.
That boat above - I built the whole thing.

you must have succeeded beyond your wildest dreams.