projekt zeal86 (build thread)

[zeal86]

Originally Posted by ka-titties

As a welder/fabricator, you should definitely have the outside of the seams welded, not the inside. If you weld only the inside, the outside is going to look weird.

Yes... I understand that... I'm looking for someone that can do it. Not one of my skills.

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[zeal86]

Originally Posted by ka-titties

As a welder/fabricator, you should definitely have the outside of the seams welded, not the inside. If you weld only the inside, the outside is going to look weird.

In my final version... aka my personal one, I want it tig welded for sure on the outside seams. I'm currently using Devcon aluminum putty on my two prototypes to see how well it works. I'm using it on both inside and outside seams... I will sand the outside seams round when dry. If it looks ok I will make others using Devcon.

@ka-titties What is your opinion on Devcon aluminum putty in general? Do you think it would hold up in this particular application?

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[zeal86]

Pics of Devcon Aluminum Putty applied on the inside and outside seams...

[Edit] Btw, the pictured aluminum is not the weldable type, it is 2024... Luckily I have access to some 6061 T6. 040" as well.











Once dry I'll sand the Devcon to the proper contours

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[ka-titties]

Originally Posted by zeal86

In my final version... aka my personal one, I want it tig welded for sure on the outside seams. I'm currently using Devcon aluminum putty on my two prototypes to see how well it works. I'm using it on both inside and outside seams... I will sand the outside seams round when dry. If it looks ok I will make others using Devcon.

@ka-titties What is your opinion on Devcon aluminum putty in general? Do you think it would hold up in this particular application?

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I dont have a ton of experience with the Devcon, but I think it should hold up for a while. My only concern would be the affect of vibration over time. But, if you're planning to build one out of 6061 anyways, get a trusted welder to stack some pretty dimes down the outsides of those joints and you'll be good to go.

[zeal86]

Devcon sanded down...









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[zeal86]

Ok... so while filing a small revision to my design the Devcon cracked and one corner opened up. Since this is only a prototype, I reinforced the corners with some angled brackets.





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[zeal86]

Started a third prototype... I corrected some things I figured out through trial and error and added a cut out of the throttle body shape.



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[zeal86]

I completed and test fit my third prototype. I just need to fill in the seams with Devcon aluminum putty then sand smooth. I will have this version painted either Beatrush gold or chrome (which will probably look more like polished aluminum) ... I will probably use this version until my final is complete then I will sell it.

Btw, 2024 aluminum is considered unweldable and the Devcon withstands heat up to around 250°F so polishing and powder coating aren't options.... that's why I'll paint these versions. My final version will be made out of 6061 T6 aluminum which is weldable.... I plan on polishing the final version.











**Top hardware is temporary. Final hardware will most likely be a counter sunk hex head.**







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[zeal86]

Found some left over hardware from my ZSpec kit... and installed them on the ECU and back of my prototype manifold cover.





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[zeal86]

Picture overload....

Saturday Hangar Shoot...






































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[zeal86]

I really like these gritty pics...





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[zeal86]

Grainy as f#@% but it has substance...




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[zeal86]

Here is a shot of my Uras driver side sideskirt. Look closely and you'll see the Uras logo and a plane.



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[zeal86]

Here is a video of my third Red Intake Manifold Cover Prototype . I've decided to polish it first...if the Devcon I used to fill the gaps doesn't look good after I polish it, I'll have it painted. It will serve as my temp until I complete my final version. Afterwards I plan on selling it if anyone is interested.

The following pics in the link above are pre Devcon but illustrate the fitment of this third prototype. The temporary top hardware will change to a countersunk hex head bolt.



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