LordWorm build commences...sort of

[LordWorm]

This has been a bit stale of late hasn't it?

I've been rather busy looking for a new job, and with new "family" commitments (inlaws, insisting on bbq's and dinners every weekend......) i've not had much time to give the car any attention.

Anyway, i'll share a few pictures.

First pic is a pick of my mess of pipes that will soon be my header Mild steel. Primary 3 and 4 are 1 piece off the bender - so they just get welded to the flange, and welded to the collector. Primary 2 is almost 1 piece, and has some rather obscure bends that apparently required the guy at the pipe shop to build a special jig to get it to work. I'm thankful for this, because this is the most complex of the primaries. Essentially all i need do is weld 3 pieces ontop of it and its done.
Primary 1 is cut and shut all the way. Which sucks... but there was no way to get it any nicer.

Second picture is a pic of 1x front and 1x rear Autoexe coilovers (i do have the other 2...before anyone asks something silly.) Picked these up for a bargain off a sport20. Unfortunately, pic 3 shows you the difference between the rear struts... no swaybar tab. Getting this welded on as soon as i can afford to have the rears rebuilt. Then they will go in and i'll have some autoexe goodness

Last pic is an "artists impression" of the header completed. You've probably seen it before, twiggy was brandishing it around a while back. By design, each pipe is within 3mm of each other (in reality, they will be less accurate, due to welding and cutting tollerences - but still better than anything out there ), they are tuned to "kick" hard at about 6000rpm...

Enjoy.

 

[Sleepy]

Once the header is tested, will more be available? If so, at what price? Through B3M?

 

[LordWorm]

Once the header is tested, will more be available? If so, at what price? Through B3M?

1 off item (well, 2 off).

Cost of building one is extreme. Pipes alone cost me over $350 for crappy mild steel, for one set.

Reason being is a custom jig needed to be made to bend the pipe.

Next I've got to design up a stack of jigs to cut the pipe correctly (there are "legs" that need to be cut off at precisely the right distance from the point where the bend ends and the pipe starts straightening etc)... then theres tooling i'll need to get (braizing torch for the collector), then theres the flanges, the pipe expanders, the welding...the inevitable stuffing up...


On paper the headers will make a huge difference - they are tuned to achieve maximum scavenging, and it will occur between the big cam hit, and the intake manifold hit, wh ich will fatten up the upper mid range nicely - but they are certainly a "race only" item, the ass will fall out of the low end power like nothing else... i can stomach it given the car is largely a toy... but for a daily....... it'll be dreadful.

of course, it can be made to opperate in a lower rev range, by simply extending the primaries.

But yeah, they'll be a headache to make - i may try and sell the design to a shop that can turn them out en masse, but thats very much a wait and see.

 

[kura808]

subbing. hehe i read the whole thing. very interesting read xD wow that thing will be revving hella high. heh slap a vtec on j/j. hehe good luck on reaching ur goal. the sky's the limit!!

 

[TreFlip999]

Sub-dizzled

 

[LordWorm]

Set backs abound this week. Having a few niggling problems with the car at the moment.

My wife has noticed a few things going wrong, which may put a hose on some of the more exciting plans, to make way for general maintenance.

My aluminium coil pack bracket has broken off, and is rattling around under there something severe. I've tied it down with cable ties for now, but i'm going to have to get a new/better bracket fabricated. I've spoken with a sheet metal place and hopefully i will be able to take a day off work early next week to get that sorted.

My new bracket idea means i will need to do something about the stock intake system sooner than i thought. Not having the money up my sleeve right now to complete the new manifold, i'll build a temporary short ram to get rid of the big intake duct at the front of the engine bay, to make room for my new coil pack bracket. I'm relocating them from behind the engine, to infront, above the exhaust manifold - so i'll need to heat shield that.

My home made throttlebody gasket is stuffed, and i am getting alot of high pitched whistles when the engine is off load - going to solve that with some high temp silicon/liquid gasket tonight.

I've also got to do something microtech rewiring to tidy up the engine bay a little because as it stands now i doubt i'd pass a tech inspection (not because its unsafe, but because it LOOKS unsafe...) - so thats on the cards tonight as well.

Further to that, the little sh!ts that live next door have seen fit to put a drill bit in my rear tyres, so they need replacing, my sway bar bushes have given way and need replacing and since putting the rock hard mounts in i've created a stack of trim rattles which need fixing with the aid of some rubber grommets.

Argh.