Verus' Shop BRZ - Development Thread

[zeal86]

Originally Posted by VeloxEric

Yessir!

I got the radiator ducts cut out and bent up. I'm somewhat satisfied with the appearance (not the greatest fabricator) but I'm thrilled with how they will function. Pictures below of them, let me know if you guys have any questions.




Driver's side


Passenger's side


Center, poorly bent , duct


Driver's side with bumper installed




Passenger side

With these installed air will be forced through the cooling stack at speed. Very excited to compare logs from highway speed tests.


I also had to weld on a bung to the other prototype radiator I had made. He wants to run a temp bung on the outlet of the radiator so I drilled and welded an 1/8" NPT on. Pressure tested to 30 PSI.







Warning, boring info below. Worked on two more blogs when I was flying over the past month. Just a few informative blog posts.

Oil Cooling Information - A blog post detailing the two styles of cooling engine oil. Most of the information is from years and years of experience working at C&R.

Mesh Defined - We realized not many people understand what it means when we say "We performed a mesh study." or "We meshed the model." Well, we did our best to describe mesh and why it is necessary in what we do.

Thanks,
Eric

Very impressive work!

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[civicdrivr]

I want to build a shroud for mine to work with the Vortech intercooler and JDL bumper bar. Might have to steal your mounting method

[zeal86]

Originally Posted by civicdrivr

I want to build a shroud for mine to work with the Vortech intercooler and JDL bumper bar. Might have to steal your mounting method

I was thinking the same thing... kind of inspired me...

I have to take my bumper off soon to modify an HKS air intake duct so I'll take some measurements for the shrouds then. I work with and have acces to aircraft sheet metal tools and materials so I'll be taking advantage of that.

This is what I have done so far..

Upper foam packing...



Lower foam packing...



Side(s) foam packing...





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[VerusEric]

Originally Posted by johan

Those shrouds are awesome. I've wanted to do something like that on past cars I've owned. What is that rubber piping you're using to seal them off? Is it self adhesive or did you use some kind of contact cement?

I refer to them as sheet metal seals. They actually slip on the edge of the sheet metal and have the large nice sealing surface already on them. Very neat for finishing sheet metal work and sealing at the same time, especially when you're not good at fabricating!

Originally Posted by zeal86

Very impressive work!

Thanks sir!

Originally Posted by civicdrivr

I want to build a shroud for mine to work with the Vortech intercooler and JDL bumper bar. Might have to steal your mounting method

Please do! I hope it spurs more people to try their own. You could technically cut these out with sheet metal shears from scratch then bend on an edge of a table.

I wish I could do something for everyone that was nice but there are far too many variables to make an effective kit for everyone. It'd have to be turbo kit and crash beam specific.

Thanks,
Eric

[johan]

Found that ish on Amazon, a few different styles that I see in your pix are all on this first page: https://www.amazon.com/s/ref=nb_sb_n...words=trim-lok

[VerusEric]

Originally Posted by zeal86

I was thinking the same thing... kind of inspired me...

This is what I have done so far..

Your foam looks pretty awesome! Love it! What kind of foam is that and how did you attach it to the parts?

So I got a bit of work done on Saturday.

Test fit mocked up of modular Tegris splitter. The idea is to be adjustable from 2-5" out from the front of the bumper. Getting closer to what I want, few more modifications and it should be ready. Two supports per side are missing in these photos.





Few more photos of the ducting and foam for the final test fit before going back together.








Took the wastegate apart to drop base pressure down from 1 bar to 0.5 bar. Simple process. May have to add a spring to get it closer to 0.7-.8 PSI base pressure but small steps. Luckily removing the wastegate is a very simple process. Trying it out on a 3-port solenoid first, then we'll hook up the 4-port.



Slight modification on billet clutch fork, which was just adding our logo onto a non-structural point on the fork. Been getting great reviews from these thus far, improved engagement, to actually engaging again, to replacing broken units.



Hoping to get a bit more done this weekend. Fingers crossed she'll be driving/testing early next week.

Thanks,
Eric

[VerusEric]

Finally installed the driver's side brake cooling kit over the weekend. This was left off for testing.

Wastegate with 7PSI spring was installed on the turbo. Really like the looks of this over the stamped Borg Warner unit, but who wouldn't? This turbo is gorgeous!







The bumper is back on the car, boost leak checked to 30 PSI (well past what I'll be running), and nearly back on the ground!

Thanks,
Eric

[VerusEric]

Injectors are in . 1300cc of 100% E85 safe awesomeness! Hoping I'll install them over the weekend coming up. Packaging goals as well...



Received our upgraded clutch pivot points as well. These are an OEM replacement to accompany the billet clutch fork. Simply made of stronger material as we were asked to produce it.









Thanks,
Eric

[johan]

Hah! When I bought my first set of ID injectors, they came in a basic plastic bag with a copied sheet with dead times on it. Paul Yaw would email back/forth with me on questions I had.

[VerusEric]

With ambient temps in the mid teens today (115), I was able to test out the ducting and see the effect it may have on coolant temps. Below are my findings based off of EcuTek logs. AC was on full blast the whole time, just like previously.

At idle, coolant temps are now 4-5 degree C higher. This is to be expected as the fans are now pulling air through a thicker cooling stack (CAC included). Before it could get air from around the CAC, which 1) reduces pressure drop for the fans to pull through and thus increases airflow and heat rejection, and 2) decreases the temperature the radiator sees which also helps cooling. Let me know if this doesn't make sense to anyone.

At freeway speeds, coolant temps are 3-4 degrees cooler. Air is being forced through the radiator where before it was spilling out/around/over. The ducts should improve cooling further at race/track day speeds.

Thanks,
Eric

[Pat]

Huh...interesting. I'm glad you gather this type of data. I'll be interested to see data from the track. I'm a little surprised the freeway testing results weren't more significant.

[gramicci101]

Eric, I thought I saw pics of a fan shroud in the works. What kind of fans are you using to test your radiator ducts? If they're OEM, would a proper fan shroud and better fans make a difference in temps?

[DHitHim]

Nice! I want to make my own too. How did you cut the metal?

[VerusEric]

Originally Posted by Pat

Huh...interesting. I'm glad you gather this type of data. I'll be interested to see data from the track. I'm a little surprised the freeway testing results weren't more significant.

Keep in mind I'm bumping up against t-stat temp. At freeway speeds before I was cruising at between 93-96 C depending on traffic. I'm now somewhere between 90-92 C. T-stat is likely slowing flow so these "tests" aren't the best at showing what is really happening; however, it is what I am capable of doing right now.

Originally Posted by gramicci101

Eric, I thought I saw pics of a fan shroud in the works. What kind of fans are you using to test your radiator ducts? If they're OEM, would a proper fan shroud and better fans make a difference in temps?

No shroud for me. SPAL fans on fan rings. The OEM unit is the best fan shroud I've seen to date. Everything available on market is bent sheet metal with stronger fans, which is not better, just more airflow from higher output fans.

Fan shrouds/fans will only be useful at lower road speeds (sub 30MPH), and if they are helpful at higher speeds than that, something is not setup correctly in the system. Think about it for a second; fan shrouds actually block airflow at high speeds; increasing drag and reducing performance.

Originally Posted by DHitHim

Nice! I want to make my own too. How did you cut the metal?

Vertical band saw. You can also use sheet metal shears. There is no reason someone can't get a bit creative on their own and make something similar for very minimal costs in tools.

Forgot, another prototype out of the printer. Final revised AOS.



Thanks,
Eric