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any idea on the minimum safe gap? I am sitting at about 1/16" and now concerned.
Don't take my word for it but after this experience I would think almost any visible gab would be enough. The lengths that it took to, to actually catch fire was. #1 the body was touching the exhaust for a length of about 2 inches. #2 running on the dyno had zero airflow on the exhaust as the fans were pushing air into the front of the car. #3 running at 5000-6000 rpm long enough that the exhaust was beginning to turn a faint pink. Real world conditions those 3 will never all be true at the same time. After it occurred we put fans on the sides blowing air across the exhaust and had no further issues. I cut/clearanced the exhaust yesterday (2 days after the dyno day).
MK3 Challenge Car, Boss 347, Sniper 2 EFI