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> Tangerine Racing Products, Horizontal Fan Cooling System in production
ChrisFoley
post Jan 21 2010, 03:48 AM
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This prototype will be ready for installation in my street car in a few days.


(IMG:http://www.tangerineracing.com/images/EnginePics/TangerineEngineCoolingSystemPrototype01.jpg)

(IMG:http://www.tangerineracing.com/images/EnginePics/TangerineEngineCoolingSystemPrototype02.jpg)

Update: 02/18/10
Pre-production discount price of $1359 in effect through 03/07/10
Paypal accepted at my website. Horizontal Cooling Fan Conversion
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FourBlades
post Feb 24 2010, 02:45 PM
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How much additional engine horsepower output do you think this set up will
cool on an extended race compared to the stock?

Is there a big difference in weight between the systems?

How did you make the wooden buck? Belt sander?

I think an old time, beige, natural fiberglass shroud would look more period.

That might be a cool alternative look.

John
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ChrisFoley
post Feb 24 2010, 04:45 PM
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QUOTE(FourBlades @ Feb 24 2010, 03:45 PM) *

How did you make the wooden buck? Belt sander?

I started with an oak tree that a friend cut down in his back yard 26 years ago.
A 7 ft log was cut from the tree and I cut that into quarters using a large hand saw and then into square lumber with my Inca bandsaw.
I stacked the boards in my basement and let them age for 26 years just to be sure the moisture content was correct.

Next I cut the roughsawn boards to approximate length and hand planed the surfaces, using two wooden planes that I made from a little bit of the oak log.
Once the boards had flat mating surfaces I bonded them together with Elmers woodworking glue.

As I made each layer I trimmed away some of the excess wood along the sides using my bandsaw, then joined the layers to achieve the full height.

I used hand chisels and my hand plane for a lot of the trimming, to avoid taking away too much too quickly. I don't want this thing to need repairs before I have even used it. (IMG:style_emoticons/default/blink.gif)
I used a router, freehand, to trim away around the neck.

Now that I am getting to the fine details I'm using two different belt sanders and drum sanders as well as hand sanding.
The prototype shroud currently fits down to about an inch above the surface, so I know it's close.
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ChrisFoley
post Mar 2 2010, 05:09 PM
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Here's a pic of the first "pilot production" shroud resting on the wooden buck.
Once I tweak the procedure a little, it should be pretty easy for me to turn these out.
Attached Image
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ChrisFoley
post Mar 2 2010, 05:25 PM
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QUOTE(FourBlades @ Feb 24 2010, 03:45 PM) *

How much additional engine horsepower output do you think this set up will
cool on an extended race compared to the stock?

I don't know. It should be able to cool any engine you can build. I've been using a similar but less efficient setup on my race engines for years. The fan speed may need to be increased for some applications by changing pulley sizes.
QUOTE
Is there a big difference in weight between the systems?

This setup is about 10lbs lighter than the factory assembly.
QUOTE
I think an old time, beige, natural fiberglass shroud would look more period.

It might look more period, but I guess I'm not really going for that look.
To me the three choices are: shiny aluminum, painted to match the car's color scheme, carbon fiber or hybrid colored kevlar/carbon fiber.
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lancelotIV
post Mar 29 2010, 03:50 PM
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wow, Chris! this looks GREAT! You've come a long way since we talked @ 2 yrs. ago (I'm working on a RSK replicar and we talked about your potentially doing this project). I think Jake has tabled his 3rd Gen DTM as he's pretty busy on other amazing projects. How much are you thinking this system will weigh? How much less should the carbon/kevlar version be?
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ChrisFoley
post Mar 29 2010, 07:13 PM
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QUOTE(lancelotIV @ Mar 29 2010, 04:50 PM) *

How much are you thinking this system will weigh? How much less should the carbon/kevlar version be?

Thanks! You know this would look very cool in a mid-engined Porsche replicar!!
The complete assembly will save at least 10 lbs compared to the removed stock cooling system but I don't have a complete set of production parts in hand yet so I can't state the exact weight.
Since the aluminum piece is quite light (about 12oz.), weight isn't much of a reason to switch to composites. The shroud represents only about 20% of the cost of production so switching to FG wouldn't save much, and CF won't increase the price drastically either. I really like the aluminum shrouds so I may need a big push to invest in a mold, unless demand exceeds my ability to produce hand fabbed metal works of art. (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif)

Unfortunately I had a minor setback today. The machine shop screwed up the entire first batch of billet crankshaft dual pulleys. (IMG:style_emoticons/default/huh.gif) They got the vee groove wrong on the front (alternator) pulley. At least they will be salvageable for full race engines with no alternator, like on my FProd car.
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r_towle
post Mar 29 2010, 07:33 PM
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How about composite pulleys and associated brackets?

Rich
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ChrisFoley
post Mar 29 2010, 07:49 PM
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QUOTE(r_towle @ Mar 29 2010, 08:33 PM) *

How about composite pulleys and associated brackets?

Rich

Now that would drive the price up! (IMG:style_emoticons/default/biggrin.gif)
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r_towle
post Mar 29 2010, 07:50 PM
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Yet drive down the weight.

Composite pulleys can be purchased...just google for a while.
You can also buy 1/2 thick sheets of carbon fiber....just like aluminum.
It can be milled with all your tools...maybe not your handmade hardwood plane....

BTW, did you dig up the iron and smelt it, then forge the blade for the wood plane you made to make the buck?

Rich
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ChrisFoley
post Mar 29 2010, 08:44 PM
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QUOTE(r_towle @ Mar 29 2010, 09:50 PM) *

BTW, did you dig up the iron and smelt it, then forge the blade for the wood plane you made to make the buck?

(IMG:style_emoticons/default/biggrin.gif)
LOL, no, but I do have books about backyard foundry technique and about toolmaking.
And I have made cutting tools from scrap iron before.
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r_towle
post Mar 29 2010, 08:48 PM
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The story of creating the buck is lacking some very important steps..

First there was the quest for Fire......................................................................and then I finally installed the cooling tin
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rick 918-S
post Mar 29 2010, 10:50 PM
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Very nice work Chris! You are a machine! (IMG:style_emoticons/default/smash.gif)
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Brando
post Mar 29 2010, 10:55 PM
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The setup is so sexy with that intercooler.

I really, REALLY wish I had the money for a Turbo TIV and a 914...

A top-down setup for mid-eighties carreras coming soon? (IMG:style_emoticons/default/drooley.gif)
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ChrisFoley
post Mar 30 2010, 09:37 AM
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QUOTE(r_towle @ Mar 29 2010, 10:48 PM) *

The story of creating the buck is lacking some very important steps..

First there was the quest for Fire......................................................................and then I finally installed the cooling tin

Hmm,
"Quest for Fire" - I liked that movie. (IMG:style_emoticons/default/blowtorch.gif) (IMG:style_emoticons/default/stirthepot.gif) (IMG:style_emoticons/default/biggrin.gif)
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Krieger
post Mar 30 2010, 08:21 PM
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Chris how the hell did you know 26 years ago that you would need this wood for making this shroud? (IMG:style_emoticons/default/stirthepot.gif)
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ChrisFoley
post Mar 30 2010, 09:08 PM
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It was the same year I bought my tangerine 914. (IMG:style_emoticons/default/biggrin.gif)
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