Cooler Ducting Project

[derbo]

Can't wait to see the test results

[Envyscorpio]

Can't wait for updates

[DRLane]

Updates -

Send cut delivered as did the various high temp silicone high density foam and silicone E gaskets I ordered.

Upper kidney access
1. Used steel HVAC material from HD to bend a sloped air direct for all the new open space created after cutting the radiator support.
2. Bolted it into the crash beam and added red silicone E seal gasket to press the steel against the SC heat exchanger. These pictures are difficult to see but oh well.

Upper radiator seal
1. Used silicone foam which in 30x20mm is a super snug and perfect fit to close the gap at the top of the radiators to force the air through the coolers. Finally no other options…

Oil Cooler
1. Ordered the trial ducting in 5052 aluminum. I'll need to remove it and shape and weld the top piece to the sides. But for now it is a test fit. Again used more of the foam to seal any escape paths and the E gasket to seal against the oil cooler. This is loosely bolted down as I'll need to remove to weld.

Had to cut the bumper a bit but this bumper is already trashed (some substantial cracks from a tire wall impact, and nothing for the Zebulon splitter. If this ducting proves successful I'll do a second pass on further improving the ducting and maybe do a composite piece.

Getting closer! Just finished a lengthy laundry list of work. I'll take it to get aligned and corner balanced and ready for some test days in prep for first NASA event.

[roastbeef]

it looks like you got it covered, but for press-on seal material, mcmaster-carr has a huge selection.
https://www.mcmaster.com/browse-sealing/edge-seals/

[DRLane]

Originally Posted by roastbeef

it looks like you got it covered, but for press-on seal material, mcmaster-carr has a huge selection.
https://www.mcmaster.com/browse-sealing/edge-seals/

Damn… Thank you!

[roastbeef]

and trim those damn hood pins doc, thats like an ounce you got there.

[DRLane]

Originally Posted by roastbeef

and trim those damn hood pins doc, thats like an ounce you got there.

Car isn't really in weight reduction mode right now, haven't / won't had time this year to grind that out. Car is sitting around 3260 right now with 1/4 tank and >530whp so I'm not super concerned for the season.

But it's definitely a must do project for 2023. Hopefully cage, wiring, major reduction… Join the ~3k crew.

[spxxx]

have you attempted to duct anything post-radiator up through your hood vents?

There's not much room, I wish we could find a thinner fan (I know this is unlikely since BMW used a PID fan with variable speed) and run a duct up to the left of the plenum intake tube.

Awesome project, I expect I'll start a similar project soon but focus on reducing drag/increasing efficiency as I'm sticking NA. Time to learn how to lay carbon and mold some ducting in that cramped space haha

[DRLane]

Originally Posted by spxxx

have you attempted to duct anything post-radiator up through your hood vents?

There's not much room, I wish we could find a thinner fan (I know this is unlikely since BMW used a PID fan with variable speed) and run a duct up to the left of the plenum intake tube.

Awesome project, I expect I'll start a similar project soon but focus on reducing drag/increasing efficiency as I'm sticking NA. Time to learn how to lay carbon and mold some ducting in that cramped space haha

You can build egress ductwork, but you'll need to tilt the radiator to accomplish this.

[spxxx]

Originally Posted by DRLane

You can build egress ductwork, but you'll need to tilt the radiator to accomplish this.

Have you seen any examples of this on a normal budget/DIY E9x car? Would love to explore how this was done without moving the motor back a foot into the firewall like the GT2 IMSA car

[DRLane]

Originally Posted by spxxx

Have you seen any examples of this on a normal budget/DIY E9x car? Would love to explore how this was done without moving the motor back a foot into the firewall like the GT2 IMSA car

Again, you can do it if the radiator is angled aggressively forward. The room is there to duct it straight up and out the hood.

[roastbeef]

one of the things i've thought about, and this isn't the norm, is a shorter, but thicker front heat exchanger to help with angling it in the limited space. think maybe 6" shorter, but about 5" thick. if you get rid of the intake snorkel, there is a pretty good amount of room for venting up.
i don't know how efficient a thicker radiator would be, if it was the best way of doing it, it would be more common.

[berns]

Originally Posted by spxxx

have you attempted to duct anything post-radiator up through your hood vents?

There's not much room, I wish we could find a thinner fan (I know this is unlikely since BMW used a PID fan with variable speed) and run a duct up to the left of the plenum intake tube.

Awesome project, I expect I'll start a similar project soon but focus on reducing drag/increasing efficiency as I'm sticking NA. Time to learn how to lay carbon and mold some ducting in that cramped space haha

I beat the piss out of my car in all temperatures for short and extended periods of time, and it never gets hot. Gets warm, but never close to the limit.
Vented hood, CSF cooling package, NA, 6-speed. They don't need much to work. Can always make them better but it's pretty easy without FI and DCT.

[spxxx]

Originally Posted by berns

I beat the piss out of my car in all temperatures for short and extended periods of time, and it never gets hot. Gets warm, but never close to the limit.
Vented hood, CSF cooling package, NA, 6-speed. They don't need much to work. Can always make them better but it's pretty easy without FI and DCT.

Yeah it seems they're pretty stout from a cooling perspective with just the Do88 package, even DCT. I just can't get the N54/S55 heat issues out of my mind. I've only ever tracked turbo cars but I'm a believer now...

[DRLane]

The ingress oil cooler ducting in composite is coming along

[DRLane]

Some updates. A little thinner than I’d like and rough around the edges but I’ll get it mocked up on the car later this week. It’s sitting at Cory’s as we strip down the interior.

I might have to send this to bigjae1976 so he can make a mold and see if we can do better / stronger / refined.

Yes, the interior is the shiny side on purpose.

[bigjae1976]

Originally Posted by DRLane

Some updates. A little thinner than I’d like and rough around the edges but I’ll get it mocked up on the car later this week. It’s sitting at Cory’s as we strip down the interior.

I might have to send this to bigjae1976 so he can make a mold and see if we can do better / stronger / refined.

Yes, the interior is the shiny side on purpose.

Yeah man, I’d be selling to give it a shot if you need me to.

That looks pretty neat. The plug fabrication is beyond me. I lack the skills to make a custom part…need to get some CAD and 3D printing skills.

[Navman56]

Props on diving into composites OP! At this point I've spent too much of my life trying to find leaks in vaccuum bags, but can still appreciate craftsmanship

[DRLane]

Originally Posted by Navman56

Props on diving into composites OP! At this point I've spent too much of my life trying to find leaks in vaccuum bags, but can still appreciate craftsmanship

I had a model I made cut in aluminum via sendcutsend. Then had a composites guy create a mold for the carbon. That’s not my handy work.