DIAMOND IN THE ROUGH 4 hour HSR mod
07-24-2009, 10:15 PM
#1
Le Mans Master
Thread Starter
DIAMOND IN THE ROUGH 6 HR HSR mod
As many of you know, bought an HSR from EBay. Here it is:
I got it today at 1:00 and i drove it down to the machine shop. They quoted me $800.00, I RAN. On the way home I decided to do what I had been planning all along. I worked on it from 4:12-8:15. Here's what I ended up with:
The plan was to do what JOBY did (!Thanks Joby!). I noticed that the back was sitting on the top of the fuel rail mounts and the front was to be 8.6 inches from the china wall.
I started by marking out the perimeter of the intake onto the plenum. The plan was to cut on the outside edge of the markings to give me room to work, I knew I would have to go further. I thought about using my grinder but if anyone of you read my previous post you know my compressor won't keep up. I'm glad i didn't.
Here's what i did:
Jig saws do not like to cut around corners. I pie cut to the edge of the line with a jigsaw and a metal blade. The jig saw worked great. At times the teeth on the blade would get caked with aluminum. You could tell right away because it would stop cutting. I would simply take a screwdriver and scrape the aluminum off the teeth and keep working.
I couldn't get around the bolt towers with a jigsaw. I took my drill and an 8mm drill bit and drilled 3 holes around the perimeter. Then I wallowed it out until they met. With the dremel and a cutting wheel I cut the bottom of the towers out.
I couldn't use my grinder so I had to find another way. This is what i ended up with, a dremel with a router attachment and an aluminum grinding bit. It was perfect for the task. I was able to adjust it to a certain height and with the help of lubricant it would slice through the aluminum like butter. After 4 hours my HSR was done. All i need to do is find someone to weld it together.
I got it today at 1:00 and i drove it down to the machine shop. They quoted me $800.00, I RAN. On the way home I decided to do what I had been planning all along. I worked on it from 4:12-8:15. Here's what I ended up with:
The plan was to do what JOBY did (!Thanks Joby!). I noticed that the back was sitting on the top of the fuel rail mounts and the front was to be 8.6 inches from the china wall.
I started by marking out the perimeter of the intake onto the plenum. The plan was to cut on the outside edge of the markings to give me room to work, I knew I would have to go further. I thought about using my grinder but if anyone of you read my previous post you know my compressor won't keep up. I'm glad i didn't.
Here's what i did:
Jig saws do not like to cut around corners. I pie cut to the edge of the line with a jigsaw and a metal blade. The jig saw worked great. At times the teeth on the blade would get caked with aluminum. You could tell right away because it would stop cutting. I would simply take a screwdriver and scrape the aluminum off the teeth and keep working.
I couldn't get around the bolt towers with a jigsaw. I took my drill and an 8mm drill bit and drilled 3 holes around the perimeter. Then I wallowed it out until they met. With the dremel and a cutting wheel I cut the bottom of the towers out.
I couldn't use my grinder so I had to find another way. This is what i ended up with, a dremel with a router attachment and an aluminum grinding bit. It was perfect for the task. I was able to adjust it to a certain height and with the help of lubricant it would slice through the aluminum like butter. After 4 hours my HSR was done. All i need to do is find someone to weld it together.
Last edited by ch@0s; 02-10-2010 at 11:53 AM.
07-24-2009, 10:58 PM
#3
Le Mans Master
Thread Starter
07-25-2009, 08:41 AM
#4
Pro
I know the end result is that the intake on the base ends up being stuck up inside the plenum. From previous post an pictures it appears that it is close the the top of the plenum. My concern would be does this effect air flow to the runners at the front of the plenum? Has anyone thought of building a plenum out of sheet aluminum where you could increase the volumn to the sides above the fuel rails, maybe keep it the same height over the intake runners, which would at least provide the same volumn and clearance for both the front and back runners?
You could even cut some of the runner down on the sides facing the widened plenum to help cut down on restrictions.
Just an idea.
You could even cut some of the runner down on the sides facing the widened plenum to help cut down on restrictions.
Just an idea.
07-25-2009, 09:43 AM
#5
I know the end result is that the intake on the base ends up being stuck up inside the plenum. From previous post an pictures it appears that it is close the the top of the plenum. My concern would be does this effect air flow to the runners at the front of the plenum? Has anyone thought of building a plenum out of sheet aluminum where you could increase the volumn to the sides above the fuel rails, maybe keep it the same height over the intake runners, which would at least provide the same volumn and clearance for both the front and back runners?
You could even cut some of the runner down on the sides facing the widened plenum to help cut down on restrictions.
Just an idea.
You could even cut some of the runner down on the sides facing the widened plenum to help cut down on restrictions.
Just an idea.
07-25-2009, 10:23 AM
#7
Le Mans Master
Thread Starter
He said it would take 7-8 hrs and 2.5 HRs worth of welding 
that means they charge 80 per HR
I did it with a dremel and a jig saw in half that time.
Maybe I can silicone it together in 30 minutes
that means they charge 80 per HR
I did it with a dremel and a jig saw in half that time.
Maybe I can silicone it together in 30 minutes
07-25-2009, 01:33 PM
#8
Le Mans Master
Thread Starter
It fits!!
This morning I put in in place with the gaskets underneath.
I took some play dough rolled it up and used it for a gauge.
I have 3/4 of an inch in front and 7/8 at the rear.
Front
Rear
The pictures are not that great, sorry.
I took some play dough rolled it up and used it for a gauge.
I have 3/4 of an inch in front and 7/8 at the rear.
Front
Rear
The pictures are not that great, sorry.
Last edited by ch@0s; 02-10-2010 at 11:54 AM.
07-25-2009, 03:31 PM
#9
Le Mans Master
Thread Starter
I spent a couple of hours porting it. Total time spent is now 6 Hrs.
now i just need to polish the intake.
now i just need to polish the intake.
Last edited by ch@0s; 02-10-2010 at 11:56 AM.
07-25-2009, 05:38 PM
#10
Race Director
just a heads up,, bolt on the throttle body and check clearance with the TB on
also, look into a nitrous TB space to move the TB forward so the TB blades don't open up above the #1 & #2 intake ports....
also, look into a nitrous TB space to move the TB forward so the TB blades don't open up above the #1 & #2 intake ports....
07-25-2009, 07:09 PM
#11
Le Mans Master
Thread Starter
, Im going to order a miniram water neck and a TB spacer. I am also going to grind the coolant outlet off. I can't go without IAC.
Last edited by ch@0s; 07-26-2009 at 12:35 AM.
07-31-2009, 04:38 PM
#12
Le Mans Master
Thread Starter
It was welded this morning. I ordered some fittings for the lines.
I also found a water neck at the parts store that will work.
Don't laugh at the paint im just playing with colors.
I also found a water neck at the parts store that will work.
Don't laugh at the paint im just playing with colors.
Last edited by ch@0s; 02-10-2010 at 11:57 AM.
08-07-2009, 12:05 PM
#13
Le Mans Master
Thread Starter
I was able to get a really good deal on a small cap dizzy and connectors.. almost there
Here is a wiring diagram for those of you who want to try this
Here is a wiring diagram for those of you who want to try this
Last edited by ch@0s; 11-24-2010 at 02:30 PM.
08-10-2009, 08:03 PM
#15
Le Mans Master
Thread Starter
I admire your "No Fear" attitude. I wish I had the time and $$ to do something like this!
08-10-2009, 10:10 PM
#17
Le Mans Master
Thread Starter
