MONZORA redux: ‘65 Corvair + ‘94 Corvette mashup for 2019 Challenge

AngryCorvair (Forum Supporter) said:

I've never been a fan of my recorded voice.

Wife said: "Who's that?"

I said: "AngryCorvair."

She said: This \../ guy?"

Haha.

Working on header heat shields today. Started with basic CAD:

then started bending up a bit of aluminum coil I got from a GRMer (who's name escapes me at the moment) in exchange for GRM Shuttling a set of tires from my hood to his:

then cut and bent some mounting tabs from an old scrap of Corvair floor:

and sparked them to the header tubes:

I think this is off to a pretty good start. I have an idea for directing airflow into them, but won't finish that til the car is back together again.

Made some some mounting tabs with my finger brake:

and tacked them in place:

Tightest gap to valve cover is about 3/8" at the back corner:

here's the concept for keeping air flowing across the headers, at least while the car is in motion:

you can also see the modified engine oil dipstick in that pic. Overall, made some decent progress this weekend.

Nice progress! Where does the front of your header cooling ducts go?

In reply to TurboFource :

2 options.  The easier way would be to grab air from under the floor, but i don't know how much air will be down there.  Probably more than enough.  The harder way is to pull air out of my center console air duct. 

Nice work on the header bags so far

stafford1500 said:

Nice work on the header bags so far

thank you! it took a bit of head-scratching until the lightning bolt of "hey, just add attachment points to the tubes". Side 2 will go a lot faster.

What about a naca duct in the tunnel feeding tube?

AngryCorvair (Forum Supporter) said:

stafford1500 said:

Nice work on the header bags so far

thank you! it took a bit of head-scratching until the lightning bolt of "hey, just add attachment points to the tubes". Side 2 will go a lot faster.

To attach bags to your tabs => safety wire

stafford1500 said:

AngryCorvair (Forum Supporter) said:

stafford1500 said:

Nice work on the header bags so far

thank you! it took a bit of head-scratching until the lightning bolt of "hey, just add attachment points to the tubes". Side 2 will go a lot faster.

To attach bags to your tabs => safety wire

que?

Instead of screws to attach your header bags to your newly welded tabs, use safety wire. No threads to get hot and gall up, easily replaceable, and light weight.

stafford1500 said:

Instead of screws to attach your header bags to your newly welded tabs, use safety wire. No threads to get hot and gall up, easily replaceable, and light weight.

i never would have thought of that.  guess i need to buy some safety wire pliers.

Safety wire pliers not needed. Just don't twist the wire more than about 8 twists per inch and you should be good. Stainless wire of any source should work, you don't need to buy a can of safety wire just for this.

They have it at HF

I've got the wire and the pliers if you want to borrow them Patrick.  Lemme know. 

In reply to wawazat :

gonna stick with sheetmetal screws for now, but you're welcome to hang out anyway. i'll be in the garage most nights this week.

Thanks for the offer Patrick!  

Didn't have garage time last night, and was limited to about an hour tonight. Installed the other header and figured out mounting tabs for its heat shield. Measured, marked, cut, deburred, and bent:

honestly I just posted that pic so I'd remember where I left them. Will attach them to the header tomorrow night.

Got all the heat shield tabs attached to LH header. Cut and bent and drilled and mounted and marked and trimmed the shield. Used a trick my Dad taught me many years ago, used a length of square tube and a hammer as a "fake brake" to put some stiffening bends in it.

Here's where I quit for the night:

Looking good.  I like the old school fabbing.  Keep up the good work.

In reply to AngryCorvair (Forum Supporter) :

I need to do this.....quite aggravating to not remember where you put something down

(note to self: If you were more organized you wouldn't have this problem)

TurboFource said:

In reply to AngryCorvair (Forum Supporter) :

I need to do this.....quite aggravating to not remember where you put something down

(note to self: If you were more organized you wouldn't have this problem)

note to self:  if you were more organized you wouldn't lose all the notes to self.

Loving your project!!

Working down the list, I figured EGR block-off was low hanging fruit, so:

grabbed the bag labeled "top end" and found the bolts for EGR and AIR hardware. Robbed the only piece of 1/8" steel plate I had, which was the "table" I made for using my horizontal band saw in vertical mode. Leftover intake gasket set gave up the AIR gasket, and the old EGR valve still had the gasket loosely attached. Using them as templates, a little Sharpie and a little drill press and a little death wheel and a little flap disc and I wound up here:

now to decide what's next...

Installed clutch disc and pressure plate:

then did practice install of transaxle just to be sure i could manage it with the tools at my disposal.

Cherry picker and HF ratchet strap FTW. While the transaxle is off, I used the flap disc to clean up the starter clearance butchery i did to the bellhousing:

what to do next? Adapter plate has to come off, as I have to drill and tap a couple new trans mounting holes, plus I have to trim some excess material for clearance and weight savings.