We are using an updated HVAC unit in this car and it required some sheet metal work to make it all fit....
Cut a hole in the firewall (this is where the old fan would have popped out)
Made a mount for it
Mount with box out
tunnel was cut a bit too
Remaking the tunnel to fit
had to make a box to cover up the hole...
Start with some cad...
Then made from metal
Continuing on...working on the intercooler plumbing
Made this tool to be able to put a bead on the IC piping.
Short one from the turbo to the IC
I'm getting better and better an aluminum....
From IC to Throttle Body
Pulled back a bit
BOV flange welded on
Air filter setup...
This car will have AC so it needed a spot for a drier. Using a e30 drier as it is easy to replace if needed.
Small bracket..cad first
welded in and drier fitted with lower AC line mocked up
Then making other AC lines...
had to weld to the 318 compressor fitting and add a crimp connector.
on the car (mock up compressor)
low side mocked up
Line from drier to evap in car. Fill port comes up from down low.
Low side...this was later changed a bit.
hold downs for everything
All the lines mocked up
Crimped and painted
Inside the car
It's hot and humid in the shop today so it's time to spend some time in the AC office and update build threads. It's hard to find time to do everything....gotta try and keep up on them and share. Pictures are a little out of order but will show them by job...
Made these little mounts for the e30 m42 lower radiator bumpers.
Welded in. Notches are to help clear the bottom of the radiator
sits pretty nice
upper radiator mount in progress
I wanted to use an OEM fan from something. This happens to be from a 2010 mini cooper and should fit the bill nicely.
made a shroud to mount it to the m42 radiator.
A little cad work
Some time at the band saw and you end up with these guys
Some welding and more cad...
Will then be powder coated!!
These little guys are to mount the intercooler at the top. I am trying to make things as hidden as possible so they weld to the underside of the core support.
Terrible picture and not pretty welds but you get the idea...
Some welded in captive nuts at the bottom.
Then bingo a pretty big intercooler in a 2002. (for those 02 guys...you can see there has been a little bit of cutting that took place here to fit things how we wanted)
This car is getting AC as well so next up we need to fit a condenser.
Sandwiched in there
Then pulled out so you can see the upper/lower brackets for the condenser
captive nuts to bolt the condenser in.
We are running a disco potato on this build...so Garrett GT28RS (dual ball bearings, blah blah blah)
Time to make it fit...
Enough for now...more coming soon.
This project has been in progress or a bit but I am working on getting back to build threads and sharing more what we do. A little history...
1975 2002 with early bumpers
Orignally an automatic but swapping to a turbo M42 and a bunch of other fun stuff.
This build is one where nothing is being held back. If metal needs to be cut to make something fit better then it is being done.
Pull everything from the interior.
Even the sound deadening.
Some rust hiding in there.
Rear subframe out
Out comes the engine
Break down the front suspension
New front struts, H&R sports and billy sports
Reinforce front subframe.
Coated front subframe
Semi boxed rear trailing arms.
Bottom side in the back cleaned and then re undercoated.
A lot more has been done already but we will leave it there for today. Will continue to update.