Progress Thread Slow Boat To China

I know downpipe routing can be a real PIA, but im not a fan of fender exhausts on a street car... That being said, with the size of downpipes i get why people do it.

Im glad you didnt do the hood route. Lots of hondas have those... nuff said.
Well I think a fox looks naked without tailpipes, so it's not really my preference to run without them. But a 4" DP will be difficult to plumb, as well as expensive. a 90° elbow is $30! Imagine all the turns. It'd be $500 just to get to the catback I bet, then another $400 for the Magnaflow CB. Maybe someday I'll do it, but for now, fenders for me.
 
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Picking up an A2A intercooler today with tubing, couplers, clamps, etc. for $100.


I do have a question though - My intake is plastic and I've been sanding it down and removing all the unnecessary BS, but now there are some holes in the top of it... Since I don't have a plastic welder, can I scuff around the holes and use fiberglass? #1, will it bond and #2 will it hold 15-20 psi?
 
Picking up an A2A intercooler today with tubing, couplers, clamps, etc. for $100.


I do have a question though - My intake is plastic and I've been sanding it down and removing all the unnecessary BS, but now there are some holes in the top of it... Since I don't have a plastic welder, can I scuff around the holes and use fiberglass? #1, will it bond and #2 will it hold 15-20 psi?
You may choose JB weld as a better solution. The intake will get hot, and fiberglass might not like that.
JB don't care.
 
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Well I think a fox looks naked without tailpipes, so it's not really my preference to run without them. But a 4" DP will be difficult to plumb, as well as expensive. a 90° elbow is $30! Imagine all the turns. It'd be $500 just to get to the catback I bet, then another $400 for the Magnaflow CB. Maybe someday I'll do it, but for now, fenders for me.
Maybe you could split the 4" DP into two 2.5/3" exhaust pipes then?
 
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It looks good, but I have a plan. If it doesn't work, those intakes are everywhere.
Yeah people about give them Away. Btw, I bought a lokar ls1 cable for my car and I'm almost sure it isn't going to work for me. It's the same length as the ford cable (4.6) so I doubt I'll use it. If you've already got a 36" ford cable you may be in good shape already and save yourself $60
 
Yeah people about give them Away. Btw, I bought a lokar ls1 cable for my car and I'm almost sure it isn't going to work for me. It's the same length as the ford cable (4.6) so I doubt I'll use it. If you've already got a 36" ford cable you may be in good shape already and save yourself $60
Somewhere in the depths of my memory, I vaguely recollect reading that a 5.0 cable is a direct fit.
 
So if you see a video on youtube of a guy in a maroon F150 getting videoed for cutting some yuppie off in Houston, that's me. I was on my way to get the intercooler yesterday LOL. F*** that guy.

Anyway, got some work done last night.

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Well, I've opened up a small can of worms. :nonono:

Ya know that lip metal that sticks out from and transverses the entire firewall? The one you always catch your hand on and cuss? That's a body seam, and I decided after a couple of barley pops last night it needed to go. So without completely thinking it through, I cut it off flush with the fire wall. Oops. Turns out that's an intersection of 3 separate pieces of metal, all spot welded together.

So I sat there pondering what to do. I tried welding it back together, but I can't reach everywhere I need to, plus the metal was ground too thin *cough cough oops again*. My next hair brained idea is to go to Home Depot and buy some 1" thin wall tubing, cut it in half long ways and weld it over the seam, heating and bending it as I go to match the contour.

If I can do it correctly, I think it'll look sharp and you'd never notice I did anything. Or it'll be another "I think I'm going to hack the front end of my car off" idea. We shall see...


On a lighter note, the guy that sold me the intercooler is selling me a BOV for $40, and he's going to TIG weld the flange to an aluminum 90° elbow and ship it all to me. Is that a cool guy or what?!?
 
Well, I've opened up a small can of worms. :nonono:

Ya know that lip metal that sticks out from and transverses the entire firewall? The one you always catch your hand on and cuss? That's a body seam, and I decided after a couple of barley pops last night it needed to go. So without completely thinking it through, I cut it off flush with the fire wall. Oops. Turns out that's an intersection of 3 separate pieces of metal, all spot welded together.

So I sat there pondering what to do. I tried welding it back together, but I can't reach everywhere I need to, plus the metal was ground too thin *cough cough oops again*. My next hair brained idea is to go to Home Depot and buy some 1" thin wall tubing, cut it in half long ways and weld it over the seam, heating and bending it as I go to match the contour.

If I can do it correctly, I think it'll look sharp and you'd never notice I did anything. Or it'll be another "I think I'm going to hack the front end of my car off" idea. We shall see...


On a lighter note, the guy that sold me the intercooler is selling me a BOV for $40, and he's going to TIG weld the flange to an aluminum 90° elbow and ship it all to me. Is that a cool guy or what?!?
Well, it's too late to tell you that if you're gonna do that, you have to weld it and cut it all in one fell swoop. (Cut a piece, then weld what you cut)
I learned the same "hard way" w/ the drip rail on the Studebaker street rod that I had before the red Mustang. Cut that b itch off completely, and the roof skin separated from the understructure it was spot welded to. That was hell.

Good luck getting that back together again. Hope we don't have to change your name to Humpty5.0.

" Humpty Dumpty was a firewall,
Humpty's owner got out the sawzall,
Now all the kings' mig welders, and all the kings' men,
Can't put Humpty together again.;)
 
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What did you end up using for that intake? Plastic welder? Curious how it will hold up to the engine heat. Others have done this and some said it wont hold up.
 
Aw man. Sucks that you got caught with your pants down on the pinch weld. I contemplated cutting mine out and welding everything smooth too, but realized the work that would go into it after seeing what that seam looks like on the interior side. Looks like you found out the hard way. Cutting it down and grinding it smooth was good enough for me.

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I fixed the firewall, with satisfactory results. I'd post pics, but the AT&T DSL service at my house bloooooows and I can no longer upload pictures. Need to call and harass someone I guess.

I also spent an embarrassing amount of money at home depot yesterday on painting and prep supplies to get rolling with that. Bought a pint of silver hammertone and a detail spray guy. Ill use the intake as the guinea pig and see what it looks like.
 
So the firewall...

Started with some round tubing and bent it to a gentle curve
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Then bent it to match the line of the seam on the fire wall
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cut it in half...
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and welded it up.
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The intake is also coming along. I still have a couple of hours of sanding to do, but it's getting there.
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