Anglin's Racer Build and History

Post by **John Brennan** » Mon May 29, 2006 1:35 pm

Every race car I've ever seen uses two hood pins-- kinda wondering why you went with three, especially as you say it was an "extra challenge."

Post by **anglin** » Tue May 30, 2006 8:01 am

John Brennan wrote:Every race car I've ever seen uses two hood pins-- kinda wondering why you went with three, especially as you say it was an "extra challenge."

The flexibility of the hood has a lot to do with it. Gene Young, the maker of the hood, recommended pinning it in the middle based on his experience on the road course. The third pin keeps the middle from flexing upward when the high-pressure air starts building up under the hood at speed.

Post by **anglin** » Sun Dec 17, 2006 5:37 am

Well, it's been a while since I posted to this thread. It's been a darn busy year since Carlisle. First there was final exams, then the military had me out of town for two weeks, then there was two weeks in Europe, and then there was five weeks of prep time for the deployment (it's amazing how wrapped around things and activities we get in life and how complicated it is to disengage yourself from it), and now I've been in Iraq for almost two months.

Don't think that just because I'm 6400 miles from home that my ability to plan projects is gone. I have a new project in the works; it's a ground-up thing. I'm going to have a little trouble getting it back to the states, but I'll work it out... Here's a picture:

Ray · Post by **Ray** » Sun Dec 17, 2006 8:28 am

You cant find a shell w/o a sunroof? Sheesh. You're a glutton for punishment.

Post by **anglin** » Sun Jan 14, 2007 10:00 am

In the good old days, back when I wasn't in southwest Asia, everytime I put together a long post I was taking away from time spent with my family or time spent working on house projects or working on the car. That isn't the case right now. It's true that I have exceptionally limited free time; however, the free time I have is fairly consistent from day to day. If I lay out a good plan I can engage in some entertaining activities. For example, I can watch a movie (it'll just take me two days) or I can do a jigsaw puzzle (it'll just take me three weeks) or I can make a post to the forum about car projects that are currently on hold but I brought all of my pictures with me (but it'll take me four days). So here it is; I've edited pictures and uploaded them on my specatular satellite internet connection.

I've purchased a lot of parts over the last two years that I really haven't done anything with. I'm well beyond "bolt-on" with my projects. Every single project I have to do at this point requires fabrication and problem solving. If I lack the skill to complete a project to my personal standard I won't attempt it. I hate to be dissatisfied with the end result. Consequently, it takes me forever to finish some projects because every project is a challenge to my personal set of skills.

One of the projects that I have many, many hours into but I've made very little real progress is the installation of the Sierra Cosworth RS front bumper. I'm not planning on slapping some L-brackets on the car and welding a chunk of metal on the bottoms of the fenders and calling it a day. I have to do stuff the excessive way. There is a tubular aluminum "subframe" in the works to adapt the XR4Ti front end to the RS Cosworth front bumper. In other words, the adapter will make the RS bumper become a (nearly) bolt-on installation.

Now, I have to warn you that I've been talking a good game, but the pictures aren't going to quite match the words. I'm still mocking up the subframe and I don't have any pictures of the parts that I've come up with. As I've mentioned in previous posts, the adapter will also have tabs, brackets and fittings for the brake cooling ducts, air inlet ducting, power steering and oil cooler, and front splitter.

Enough chatter; it's time for some pictures of the progress I've made.

Prior to the project starting, I took several pictures of the structure of the RS bumper so I could start "imagineering." Here's some pictures of an RS bumper from an angle you may have never seen before:

The first step of the installation is the most obvious; the stock front bumper has to be removed:

The front bumper off and the Rapido IC fully visible:

The metal part of the front bumper sticks out a substantial distance. I can't wait until that trait is missing from my racer. Here's the side view of the metal bumper installed:

A closer shot of the side of the front bumper area. The metal structure will have to be modified to accept the RS bumper. The problem is that the bracket that comes off the bottom of the fender is not only for the mounting of the stock XR bumper, but it provides stiffness and support for the fender.

The way it supports the fender is visible here.

Post by **anglin** » Sun Jan 14, 2007 10:27 am

The Rapido intercooler doesn't use the most impressive mounting system. It's location, well forward of the stock radiator puts it smack-dab in the way of the RS bumper, as you'll see in the few pictures. While working on the mock up, I spent a lot of time looking at the existing structural design a bolt holes. The bottom part of the stock bumper is supported by two plastic bits that come from a portion of the metal structure that really doesn't do much. My design is likely going to avoid the metal section that protrudes from the bottom of the stock "frame rails" so they can be removed since they won't serve any purpose with the RS bumper. This allows that big chunk of metal to be removed if the installer wishes. Here's the underside:

With the metal bumper removed, the front end takes on a different shape:

Okay, so the Rapido IC does use those square sections of metal. Since the RS bumper and the Rapido IC are incompatible, the Rapido IC is going away. Here's the front end, sans metal bumper:

Here's the Rapido IC behind the RS bumper mocked up. The lack of fitment isn't quite so obvious yet.

Oh yeah; it's obvious now that the two weren't meant to be together on the same car. I just don't think I'll be cutting a genuine RS bumper to fit it around the average-performing Rapido intercooler.

Goodbye metal bumper! It's a shame my mc2racing web page sticker is going away with the plastic bumper. I'm fairly fond of that simple vinyl sticker. It's just about as understated as obnoxious can be. FWIW, I'm considering making some sort of crash structure to tie the two "frame rails" together more solidly. The aluminum bumper at least ties everything together with a substantial chunk of metal that can help hold everything together in the event of an impact with something narrow like a telephone pole.

With the Rapido intercooler removed, the mock up of tbe bumper takes on the correct appearance of the RS bumper on the front end. It's a darn shame that this leaves my racer temporarily intercooler-less.

An underneath-shot of the test-fitted bumper. The square sections of metal coming off the bottom of the frame rails are really advertising their worthlessness now.

Now that the bumper is close to where it needs to be, I can start comparing locations of bolt holes to figure out what is going to be required for the design of the adapter. Here's a picture of the underside of the frame rail and the mounting holes in the bumper.

Post by **anglin** » Sun Jan 14, 2007 10:47 am

Just like with any other project I do, there's about a dozen other projects that are related (each with their own subprojects). Since the Rapido IC had to go away, it must be a good time for the Pace RS500 intercooler to get installed. While I am doing that it only makes sense to install the C&R radiator I have as well. Of course, that radiator is going to get modified to accept AN fittings and the intercooler will get plumbed with aluminum tube.

A new cooling fan arrangement is "required" so wiring will also have to be done. Watch the list grow!

Here's the old radiator just waiting to be removed.

Here's the stock power steering fluid cooling loop. It is affixed to the structural support to the fender, so that's going to have to go away sooner rather than later. It's going away anyway, it just has to get incorporated earlier in the process than I would like.

I don't intend to install driving lights in the bumper. I'm going to skip right to the brake cooling duct inlets. Here's the opening and dimensions of the opening for selection of the correct inlets.

That's 6" x 3.5" or so.

So there you have it. New pictures, even though I haven't seen this car since August of last year. I have more to share. I'll do that when I get a chance.

Ray · Post by **Ray** » Sun Jan 14, 2007 8:13 pm

Why are you going with the RS front?

Seems like too much of a headache. Just ship it to me, i'll keep it off yo' mind.

Black94 5.0 · Post by **Black94 5.0** » Wed Jan 17, 2007 5:29 pm

Wow, great pics....Those were super helpful as I was looking at getting a used Rapido IC and standard Cossie bumper....

Thank you....

Frag · Post by **Frag** » Wed Jan 17, 2007 8:33 pm

Black94 5.0 wrote:Wow, great pics....Those were super helpful as I was looking at getting a used Rapido IC and standard Cossie bumper....

Thank you....

How about a cossie intercooler to go with the cossie bumper!

worked_xr · Post by **worked_xr** » Fri Jan 19, 2007 10:49 pm

Frag wrote:
Black94 5.0 wrote:Wow, great pics....Those were super helpful as I was looking at getting a used Rapido IC and standard Cossie bumper....

Thank you....
How about a cossie intercooler to go with the cossie bumper!

I second that!

Post by **Grayson** » Sun Jan 21, 2007 1:06 am

That Pace intercooler that he already mentioned will likely outperform a Cossie intercooler. The Pace IC isn't big on thermal mass, but the wetted area pwns.

Post by **DPDISXR4Ti** » Sun Jan 21, 2007 10:52 am

Grayson wrote:That Pace intercooler that he already mentioned will likely outperform a Cossie intercooler.

Have you ever seen, felt, touched, and made love to a real Cossie IC, you fawkin book-smart child you!?

Post by **anglin** » Sun Jan 21, 2007 12:55 pm

DPDISXR4Ti wrote:
Grayson wrote:That Pace intercooler that he already mentioned will likely outperform a Cossie intercooler.
Have you ever seen, felt, touched, and made love to a real Cossie IC, you fawkin book-smart child you!?

That's awesome!

Anyway, lack of thermal mass it is... When I looked at/handled the Forge RS500 replica the first time I was astounded by its mass. I posted the details in the "Official 'How Much Does it Weigh' Thread" in the FAQ section, though the weight of a Forge RS500 intercooler isn't actually asked about much. The Forge weighs 22.5 lbs vs. the Pace at 9.5 lbs.

There is a genuine back-to-back comparison between RS500 intercoolers; the knock-offs versus the real thing. If I remember correctly, at least one knock-off outperformed the RS500 OEM IC. Of course, the RS500 IC outperforms the smaller Cosworth RS intercooler in everything I've read.

yottabit · Post by **yottabit** » Sun Feb 04, 2007 3:34 pm

I just read through this whole thread and it was pretty impressive!

I'm in machining 2 at my school and I often take our machines for granted. Lightening that strut brace made me laugh. Too bad you don't have power feed!

You're use of lightweight stuff is ridiculous. I feel stupid making my exhaust out of aluminized steel now. I think maybe I should make the turbo-back titanium with an aluminum tailpipe...

Any clue when you get to come back from overseas? Good luck anyways, I look forward to seeing more of your work!