Cold Air Box Fabrication

[2FAST4U]

Time to test my fabrication skills. I plan to (try to) fabricate this cold air box from .063 6061 aluminum sheet. Sides will be attached via brazing (I hope). Sprayed one panel with Dykem tonight and will begin laying out the dimension for the holes.

https://thumbs2.imgbox.com/bd/df/MsaB7ePm_t.jpeg (http://imgbox.com/MsaB7ePm)

Dimensions plotted
https://thumbs2.imgbox.com/62/86/AUT2JcDC_t.jpeg (http://imgbox.com/AUT2JcDC)

Ready to start
https://thumbs2.imgbox.com/50/00/qOw2O01a_t.jpeg (http://imgbox.com/qOw2O01a)

[Jetfuel]

Heck yeah...give it world...we will be watching this project

Jet

[aquillen]

4-sure. Will be a jewel if you match or beat that picture.

Redding - great place to live. In 2007 I was out there several times installing radiology software at Advanced Imaging - when Dr. Hecht was building and opening his center. Took my wife along on the last trip to see the sights like your cool glass bridge. Next we went over the hill, stopped in Eureka (toking center of the world?), rode the "skunk train" and took in the Avenue of Giants, etc.

[2FAST4U]

All dimensions laid out on a sheet of .063 6061-T6 aluminum. Checked and rechecked, and checked again. Now waiting for a special size hole cutter for the air horn holes. Time to make some chips!

https://thumbs2.imgbox.com/b4/c9/ruKulcnQ_t.jpeg (http://imgbox.com/ruKulcnQ)

[2FAST4U]

Received my new carbide tip 2.125 hole cutter for the air horns. Cuts like a hot knofe through butter. Expensive but so much better than the **** at Home Depot or Lowes

https://thumbs2.imgbox.com/85/6f/5zppO7ek_t.jpeg

(http://imgbox.com/5zppO7ek) https://thumbs2.imgbox.com/21/0e/9yMl9URt_t.jpeg (http://imgbox.com/9yMl9URt)

[2FAST4U]

Nearly finished with the base plate. Air horn holes and fuel inlet reliefs cut. Next are the access holes for the needles and jets.

https://thumbs2.imgbox.com/51/8b/nYxloS1M_t.jpeg (http://imgbox.com/nYxloS1M)

[2FAST4U]

Base plate complete. Assessing rake for side pieces

https://thumbs2.imgbox.com/d8/40/8ghGHoTc_t.jpeg (http://imgbox.com/8ghGHoTc)

https://thumbs2.imgbox.com/c9/92/GiBTi7jq_t.jpeg (http://imgbox.com/GiBTi7jq)

[Jetfuel]

That looks really cool, and as you assess the side pieces may I suggest slope up and fallow the string hood lines and round off the forward corners....just like post 1
I could be wrong....but that's why we're here

Jet

[2FAST4U]

I plan to

[Jetfuel]

Yeah but with your own spin....shallow grooves milled into the side walls will set it off.".just saying

Jet....

[2FAST4U]

First shot at making the sides came up close but failed. Bent one corner a tad short. Time for attempt #2

https://thumbs2.imgbox.com/83/24/d7jFdpIy_t.jpeg (http://imgbox.com/d7jFdpIy)

https://thumbs2.imgbox.com/84/3b/Xt0vQGXK_t.jpeg (http://imgbox.com/Xt0vQGXK)

[2FAST4U]

Success!

Time to weld

https://thumbs2.imgbox.com/25/26/IceJhxzY_t.jpeg (http://imgbox.com/IceJhxzY)

https://thumbs2.imgbox.com/a1/29/IpwQKLJb_t.jpeg (http://imgbox.com/IpwQKLJb)

[65 Cobra Dude]

Nice work Bill!!!

Henry

[Ducky2009]

Nice!

[2FAST4U]

I remade the sides. I raised the front 1-1/2”. Now it more closely resembles the one I copied and better fits under the hood. There’s a small gap in one corner but I think it can be welded closed.

https://thumbs2.imgbox.com/b3/58/VB9Wjlm0_t.jpeg (http://imgbox.com/VB9Wjlm0)

[URL=http://imgbox.com/q5uG35vB]https://thumbs2.imgbox.com/36/83/q5uG35vB_t.jpeg[/URL

[SerpantFL]

Nice job! I'll bet those carbs will thank you for that fresh air... Anthony

[2FAST4U]

All set to take to the welder tomorrow

https://thumbs2.imgbox.com/45/46/OIowKAFv_t.jpeg (http://imgbox.com/OIowKAFv)

[2FAST4U]

I got my cold air box back from the welder. Disappointed in the quality of the welds. He also tacked the underside which I didn’t want. I spent the first day using a flap,wheel on my grinder to blend the welds on the outside .

https://thumbs2.imgbox.com/95/9c/HQWkRBUE_t.jpeg (http://imgbox.com/HQWkRBUE)

https://thumbs2.imgbox.com/b1/80/Y9OpYwh0_t.jpeg (http://imgbox.com/Y9OpYwh0)

https://thumbs2.imgbox.com/48/a9/DMNdp3WU_t.jpeg (http://imgbox.com/DMNdp3WU)

[2FAST4U]

deleted.

[2FAST4U]

I added notches to clear the fuel inlet fittings

https://thumbs2.imgbox.com/6d/57/5KJqlcEz_t.jpeg (http://imgbox.com/5KJqlcEz)

https://thumbs2.imgbox.com/ce/84/EOYK9kdP_t.jpeg (http://imgbox.com/EOYK9kdP)

https://thumbs2.imgbox.com/f9/5d/ZSy4Kqxf_t.jpeg (http://imgbox.com/ZSy4Kqxf)

[2FAST4U]

Finished sanding the inside. Time for the outside

https://thumbs2.imgbox.com/3a/68/3XarMrVx_t.jpeg (http://imgbox.com/3XarMrVx)

[2FAST4U]

All finished and installed. Polished the air horns while I was at it.

https://thumbs2.imgbox.com/a6/ca/0O8XxZZk_t.jpeg (http://imgbox.com/0O8XxZZk)

https://thumbs2.imgbox.com/ff/32/MkaBTbiW_t.jpeg (http://imgbox.com/MkaBTbiW)

https://thumbs2.imgbox.com/66/c1/duGnpYZf_t.jpeg (http://imgbox.com/duGnpYZf)

[chargerbill]

Very impressive.
I need to learn how to do that.

[Straversi]

Beautiful!
-Steve

[cgundermann]

Very, very cool!

Chris

[mt10flyer]

Excellent work! From what I can tell this is the engine setup I would do. Can you give more details on the engine and carb specs? Did you build the engine up yourself? I have built some Triumph and MG engines and would be a little lacking (OK...a lot lacking) in having any experience on what the best components would be for one of these thunderous engines. I know Webers and have good experience getting them to sing together, but the rest...ugh

[2FAST4U]

Block is 90 roller block. 030 over, squared, and decked.
Crank is Scat forged steel stroker.
Probe industries forged I-beam rods, polished, full floating
Probe industries forged aluminum pistons for TW heads, domed, sides coated with Teflon
Probe industries lightweight steel wrist pins
Mains align honed
Everything balanced
Comp Cams Pro Magnum roller rockers
Hydraulic roller cam (.571/.587 lift, 112 LSA)
Aviad reproduction original oil pan
Weber 48 IDA carbs modified for low speed driving
Blue Thunder reproduction Weber manifold
Twisted Wedge aluminum heads (2.02/1.60, 65cc chambers)
Heads and intake manifold port matched and polished
Size 60 weber jets
Jim inglese fuel/water inlet with correct hoses and clamps
Stamped steel valve covers modified to original look
Period correct breather caps and decals

I have a total of $14,045 in the engine alone. Yes, I built the engine myself.

[mt10flyer]

Thanks for the response!!! Great info.

[Jwymore]

These specs are pretty much what I am looking to do for my Daytona Coupe. Have you had this on the dyno? I'm guessing something in the 425 Hp range? The step by step on the air box is very helpful too as I will at some point be fabricating one.

[2FAST4U]

No dyno