Project "independence day"IRS and 3500 swap

[Driver_10]

I had put the project down for a long time after it got flooded in Ike a couple of years ago. Now that Ive got a shop and some decent equipment, I can move on with completing it. Who knows, maybe I wont grenade the engine this time like I did the 3400.

[pocket-rocket]

Wow, man. The progress and quality of it looks good I envy your shop too.

Sent from my HTC One X using Tapatalk 2

[Driver_10]

I got a bit more work done on strengthening the brackets. I couldnt find a aluminum of satisfactory thickness in since all of the metal supply shops were closed monday. I bought some 110 wall aluminum tubing and used it to make the reinforcement for the brackets.

I didnt come out as pretty as I would have liked, but its finctional.


I even added a boss for the pulley. Replacing a worn pulley will be a snap






It mounts well and feels good and sturdy. I also got the DS pump bracket finished.


I first tried making it out of aluminum, But I didn't like the feel of it. So I went ahead and made a sturdier on out of steel. It should be plenty sturdy!


Starting to look more like a proper race engine

[Driver_10]

Its been a nice day with a surprise cold front coming from the North west today. I bought a few more fabbing supplies (pipes, all-thread, sanding belts, cut-off wheels, etc) I started on the turbo mounting bracket today. I started with two pieces of all-thread and cut some spacer tubes to make up the supporting body of the mount.

I felt that this was sufficient to maintain the weight of the turbo.


[IMG]http://sphotos-b.xx.fbcdn.net/hphotos-prn1/644474_417310378326131_1611642167_n.jpg[\IMG]

After putting a piece of string around the oil-pump pulley to check the size, I immediately noticed some new clearance issues. The turbo-mount was interfering with the oil pump belt route. I went ahead and engineered an additional bracket to solve the problem.








Its not much of an update, but I was happy with the small bit of progress, so I posted. Hopefully Ill have some bigger things done tomorrow.

[pocket-rocket]

Fixed your borked img link

[Driver_10]

Fixed your borked img link

chankyew!

[Driver_10]

I tweaked the oil-pump pulley a bit and got the turbo mounting bracket in its place. Slowly coming together.

[Driver_10]

I quit messing with this thread for a bit, guess ill update for the hell of it.

I got the motor mounts finished and notched the firewall to make room for the driver-side cylinder head. (still needs more slicing)









I used some universal bushings and just altered the lenth.


















The firewall was hammered a bit to get the engine squeezed into place and the spot was marked. After the engine came back out, the firewall was sliced and a panel was made. I should be able to remove the cylinder head install headers now easily without having to remove the engine through the bottom.











The final mounting for the engine is about 2-3 inches back (seems accurate :P) and 4 inches downwards from the original v6's spot. The crank snout sits behind the front spindles now.

[Driver_10]

I got a woodward racing steer column in the car. The initial bracket that came with the unit had to be altered, so it fits my long frame rather comfortably well now. Both the steering wheel and the shifter sit level to one another. I no longer have to reach forward for either now.





Came with a nice MOMO steering wheel too!

[Driver_10]

Since the engine is equipped with dry-sump oiling, I needed to find a suitable spot to install the oil tank. After some careful deliberation I had decided to drop the air-to-air IC in the front of the car to make space for an oil-tank that would sit in the pass side front corner under the bumper cover.
(bye-bye ol buddy)


I sold my old air-to-air unit and bought a cheap used water-to-air unit that will flow 700cfm worth of air. The heat exchanger is a 6 x 2.5 x 21inch unit that will fit in front where the old IC was before. The IC only good to 600hp before becoming restrictive, but that's well matched for an engine that will be making no more than 510 at the wheels. (about 590-ish at the crank)

The benefits of this new set-up will be faster boost response since the turbo routing is so short. It should have better air-flow efficiency since the pressure drop is only 1/3 that of an equivilant air-to-air IC.






I went ahead and made a "floating mount" for the IC to nudge it clear of the space needed for the oil tank. Looks pretty good.






By this point, the front cross-support had to be modified to make room for the IC and AC condensor



I went ahead and flipped the AC condensor over to put the hose fittings on the right side. Im quite happy with this.

[Driver_10]

I finished up the dry-sump oil-pan yesterday...

My aluminum welds are still "noobish", but they dont leak. Good design, mediocre welding...

One out of two aint bad.

[bob442]

Ohhhhh! Pictures!!!!!

[unchained01]

Ohhhhh! Pictures!!!!!

Not bad at all good design !!
May i ask where you are going to supply the turbo from The filter sender port ?? and where will it retun ? I missed it somewhere LOL

[Driver_10]

Not bad at all good design !!
May i ask where you are going to supply the turbo from The filter sender port ?? and where will it retun ? I missed it somewhere LOL

Im using a "t" that will be plumbed directly on the oil feed hose and send cooled, filtered delicious oil to the turbo .
The oil will return to the pan via 10an welded fitting.

Ohhhhh! Pictures!!!!!

Have some more!

Added some anti-foam baffles...






After that, it was measure, cut and weld (repeat steps)












My DS system is nearly complete!

[unchained01]

Nice !!!