RyanB's Baja

[RyanB]

Weird. I swear I had an old blog from a few years ago here. Cant find it now. So I'll start a new one.  I finally started working on my Baja again.

Here is a thread that still exists on ShopTalkForums.  http://www.shoptalkforums.com/viewtopic.php?f=28&t=104258

And here is some of the latest Updates:

Picked up my intercooler this past weekend. Thanks Typ4!  It was a bit larger then I expected. Now i have to figure out where to put the VANE and how to route hose to it since the intercooler hangs well over halfway over the 90 degree elbow.  Suggestions welcome!

Ended up replacing almost all the oil and water lines going to the turbo. At least the oil lines do not leak now. Dont know yet about the coolant lines.  With the intercooler there I will have to clearance the Baja cowl that comes across. The nice thing is the airflow should be directed right over the intercooler. Yay!

Below are some pics.  Keep in mind that the exhaust you see is NOT the final location. It's just a mock up to get a feel for how things will fit. Will do the finished one once I get the turbo flange from Mark.  I also got the cage put into the car and quickly found out I either need to drastically clearance part of the fan cage or lay the radiator flat.  The way I mounted it, it's like at a 85 degree angle.

One other thing I help with. See the second pic. Just below the exhaust is the diaphram that controls the wastegate. It has a line that comes up to a T that goes into the intake there just before going up to the intercooler.  With Turbo Pressure there is no way there is Vaccuum there right?  Where do I put the other end of the T to?  Does that really go behind the throttle plate for true manifold Vaccuum? Or does it go somewhere else? If it goes to manifold Vaccuum... That confuses me because the T goes to turbo pressure.  arg!

[CatBox]

you need a bigger shoehorn.

looks like its going to be a handfull when you stomp the pedal.

[RyanB]

you need a bigger shoehorn.

looks like its going to be a handfull when you stomp the pedal.

Haha! Yea, thats the point! Actually,  I am probably going to have to keep my foot out of it for sure.  I have a bus box redux transmission I want to put in this thing so I am gonna try and get that built up.  2nd gear pops out on the current trans so I need to be careful.

This weekend I plan on getting the Coolant system worked out and see if I cant get the thing running full time instead of just 2 0second intervals! heh.

[CatBox]

all i can say is, Yes!

[Thanney]

Looking good Ryan, what engine do you have in it?

[CatBox]

it looks to be a FOrd 2.3L form a fuel injested car. 

Since it has a hair dryer attached I am leaning towards a turbo Thunderturd?

 ;D

[RyanB]

LOL Peter. Yes, it has a hairdryer attached.  It is a 2.3 Ford Turbo Fuel Injected.  I honestly don't remember now what it came out of as I am the second owner of it outside it's original car and I've had it a few years now.

Still working on the cooling system. But I went to pick and pull this weekend and picked up a few things. I got a remote reservoir, an alternator bracket and a throttle bracket. I've had to make a few changes as far as the radiator so I am not further along as I would like. It's coming though.  I've procrastinated on this project far too long. I wanted to do this 2 years ago. haha.

Dont remember if I said something already but damn that inter-cooler is big. I am going to have to cut my cowl to get it to fit over it now.   >:(

[Kev]

Man Ryan, that thing is going to be a monster when you stomp on it!   8)

[RyanB]

Before I get too far into the radiator position... due to fan placement issues. I am not running things the way I originally envisioned.

Originally I wanted the fan on the engine side, pulling air through. This would suck air up from "underneath" the car or just over the transmission.

What I found was allot of fit problems with the fan facing that way. I've since thought about it and I have flipped the fan to the other side. This would then make it so that it is pulling air from near the engine and towards the transmission/bottom of the car.

My question is, is this already a low pressure zone so it would almost be sucking air anyhow? Also, with the rear Baja cowl it would seem that allot of air is going to be forced into the area were the radiator is anyhow. Combine that with the possible low pressure area (at speed) I imagine it would create a decent airflow as well.

Thoughts?

[StevesBug]

I don't know about the normal air flow, but it sounds like once you're moving a duct system either
on the roof or in the panels just behind the doors could collect air and direct it to your radiator going
the correct direction. The fan would then be most useful at low or no speed situations.
   You might consider a block of wood under the gas pedal while you learn this beasts' temperment? :o

Steve

[RyanB]

So I spent all Sunday for the most part working on the Baja.  Mostly it was cleaning up and routing the wiring. I did get the remote reservoir setup though. See 1st pic.  Now working on the coolant lines to the radiator. Once the coolant lines are run I will be concentrating on the throttle cable. I have an idea for it just not sure how well it will work.

It seems Fastenal are not open on Weekends. how lame is that.  I wanted to get a nut to weld in for my O2 sensor.  Local hardware store didn't have the right thread.

Remote reserviour is installed there on the right.


A look at the package tray area. I've cleaned up the wiring.


The Radiator and support cage installed. Once I feel comfortable with how it all fits I'll box it in with sheet metal.


Just a look with the back seat up.

[TotallyVW]

Nice work.  Can't wait to see it on the road.
 

[Kev]

Wow Ryan that is some serious metal hanging off the back!  8)

[RyanB]

Spent a ton of time this weekend on working on this baby.  I got all the water lines worked out. Sadly, I must have hit one of the lines internally as I ended up with a leak in the radiator.  However I started the car and ran it for a good 30 minutes.  Running really rich because I do not yet have the O2 sensor.  Still waiting on Blink Chicken Racing to finish up the flange for me so I can finish the exhaust.

I had an interesting surprise though when I filled the car with water. The guy who had the engine before me apparently removed the intake manifold and the gasket came apart. Well he must have cleaned it off the manifold but not the head. He put the manifold back on. Well this left big gaps and when I put the water in it came pouring out between the head/manifold. Uhg!

I'll take some pics tonight or tomorrow. I am taking the radiator in today for repair. Hope to pick up a weld in bung for the O2 sensor somewhere today as well, going to pick up a couple so I can toss one in the exhaust I have now and one on the Exhaust flange I get from BCR.  Hoping that by Tuesday night I'll have it all back together and purring.  I want to make it to the Cruise to the Beach!!

[RyanB]

Picked up an extra long throttle cable today as well as a new fuel gauge and sending unit. I have the mechanical one in my 66 and while I think it's kewl and all the cable periodically gets stuck in weird places so I never REALLY know how much gas was in there. I also picked up a weld in bung.

Now for the sad part. The radiator shop wouldn't touch my Radiator. So, I need to pull some fins off and see if I can repair it with solder I guess. Uhg.

Well wasn't able to solder it. The solder just runs off. I then crimped the whole shut and it wouldn't even seep into crack. More and more frustrating. Spent 3 hours last night settings up a way to pressure test it and the solder and all for naught.

Since I had already done a bunch of custom work to make the radiator fit, I dragged the bad one down to DIP and they matched it up. I now have a new radiator which has a better mount system and a much better (imho) fin cooling area. It set me back 75bones. So that's probably about what a repair would have cost had they done it.

So, over the next few days, the plans are now:

Finish throttle system: I have to create a couple custom mounts and make it work.
Install Radiator: Should be no brainier, I've already done all the work previously. Cooling system is finished.
Install Exhaust: Still waiting to hear from Mark on a new Flange. I picked up a weld in bung and will just make what I have work for now till I get the permanent part.
Gauges: I picked up a new fuel sender and fuel gauge. Money is tight so I couldn't go with the white face gauges. I still need to come up with a Tach, Oil Pressure and Water temp that are electronic. I have a final opening and not sure what I should be in it. Boost gauge?

Thank you to Peter, he gave me some seat covers and some gauges. The sad part is no way will they work. The distance is too great from the dash back to the motor. I'll bring the gauges back to you Peter.