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Thread: Cold Air Box Fabrication

  1. #1
    Senior Member 2FAST4U's Avatar
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    Cold Air Box Fabrication

    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.



    Dimensions plotted


    Ready to start
    Last edited by 2FAST4U; 11-04-2019 at 08:52 PM.

  2. #2
    Senior Member Jetfuel's Avatar
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    Heck yeah...give it world...we will be watching this project

    Jet

  3. #3

    Yes, I love Technology
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    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.

  4. #4
    Senior Member 2FAST4U's Avatar
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    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!


  5. #5
    Senior Member 2FAST4U's Avatar
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    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




  6. #6
    Senior Member 2FAST4U's Avatar
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    Nearly finished with the base plate. Air horn holes and fuel inlet reliefs cut. Next are the access holes for the needles and jets.


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  8. #7
    Senior Member 2FAST4U's Avatar
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    Base plate complete. Assessing rake for side pieces




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  10. #8
    Senior Member Jetfuel's Avatar
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    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

  11. #9
    Senior Member 2FAST4U's Avatar
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    I plan to

  12. #10
    Senior Member Jetfuel's Avatar
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    Yeah but with your own spin....shallow grooves milled into the side walls will set it off.".just saying

    Jet....

  13. #11
    Senior Member 2FAST4U's Avatar
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    First shot at making the sides came up close but failed. Bent one corner a tad short. Time for attempt #2




  14. #12
    Senior Member 2FAST4U's Avatar
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    Success!

    Time to weld




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  16. #13
    Administrator 65 Cobra Dude's Avatar
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    Nice work Bill!!!

    Henry

  17. #14
    David aka Ducky2009 Ducky2009's Avatar
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    Nice!
    MK4 Build #9035 Delivered 2/17/17, First Start & Go-Kart 6/2/17, Licensed 9/1/17
    Paint - Lightning Blue Metallic, No Hood Scoop, No Stripes
    Gen 2 Coyote Engine & TKO-600. Solid Axle, 8.8-3.55, Power Steering, Power Brakes, Dual Roll Bars
    Heater and Glove Box, Drop Trunk, Wipers, Radio, FFR Vintage Gauges, Custom Dash
    Build Thread: http://thefactoryfiveforum.com/showt...MK4-Build-9035

  18. #15
    Senior Member 2FAST4U's Avatar
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    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.



    [URL=http://imgbox.com/q5uG35vB][/URL

  19. #16
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    Nice job! I'll bet those carbs will thank you for that fresh air... Anthony

  20. #17
    Senior Member 2FAST4U's Avatar
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    All set to take to the welder tomorrow


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  22. #18
    Senior Member 2FAST4U's Avatar
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    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 .






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  24. #19
    Senior Member 2FAST4U's Avatar
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    deleted.
    Last edited by 2FAST4U; 01-15-2020 at 07:44 PM.

  25. #20
    Senior Member 2FAST4U's Avatar
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    I added notches to clear the fuel inlet fittings






  26. #21
    Senior Member 2FAST4U's Avatar
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    Finished sanding the inside. Time for the outside


  27. #22
    Senior Member 2FAST4U's Avatar
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    All finished and installed. Polished the air horns while I was at it.






  28. #23
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    Very impressive.
    I need to learn how to do that.

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  30. #24
    Straversi's Avatar
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    Beautiful!
    -Steve
    Mk IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17, Registered and Completed 10/18/18. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build Graduation Thread: https://thefactoryfiveforum.com/show...-Roadster-8901

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  32. #25
    Senior Member cgundermann's Avatar
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    Very, very cool!

    Chris
    Generation 3 Type 65 Daytona Coupe Complete Kit #151885 received May 6, 2022. Gen 3 Coyote, IRS, Tremec TKX, American Powertrain hydraulic throwout bearing & Wilwood brakes.

    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

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  34. #26
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    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

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  36. #27
    Senior Member 2FAST4U's Avatar
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    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.
    Last edited by 2FAST4U; 03-04-2020 at 08:32 PM.

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  38. #28
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    Thanks for the response!!! Great info.

  39. #29
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    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.

  40. #30
    Senior Member 2FAST4U's Avatar
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    No dyno

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