Bonnet radiator outlet vent; Mk.0 (picture heavy)

Following on from this post http://ift.tt/1oQ3GT9, this post is about the bonnet duct I came up with. This is a prototype and I will make another using the car's own bonnet once I am happy with the whole set up.



I use a differential pressure gauge (as mentioned in this old post - http://ift.tt/1p2vTDQ , which is now £24 :( ) with one tube in the cabin and one at different places on the bonnet to measure where the lowest pressure was and then transversely to see how wide to make it.



Once I had some positions I made up this using my pressure points and a vaguely attractive shape that was a bit less blunt then a rectangle:





I then masked it off so that it would make it easier to cut it out with the grinder. The grid was me seeing what mesh would look like, it's not of significance:





The rectangular part was cut with a thin grinding disc







The rounded edges were cut with a jigsaw, with a really sharp new blade and on a slow setting with time to cool every few inches:





You can see cuts into the strengtheners, which I will avoid doing in Mk.1





It was then primed grey





and lacquered:





It was then masked up to prevent scratches from the mesh:





The mesh is tucked in between the skin and the strengtheners:











Some 7mm black rubber edging is then applied along the sheetmetal, and is held underneath between the bonnet skin and the mesh, so it won't pop out





The bonnet was then fitted (excuse the colour mismatch - it's a different primer). The next 'volunteer' bonnet can be seen in the background.





Not a flattering angle:





Next the radiator top surround was cut with a thin grinding disc:





The spare wheel well wall/radiator duct back plate was cut down to the box section:





Carboard was then employed for filler panel templates:









then made in sheet metal:





This is then formed around the various nearby panels and riveted in place:





Then grooves were cut for the bonnet stay:





and the stay's clip was re-used, just moved about 2 inches:





Two panels were made to fit between the base of the radiator and the spare wheel well.





One will not fit because of access and the protrusion of the fan, so the short one goes in first, tucking under the fan ,





then the long one goes in.





They bolt together, and the same bolt is used to hold them both to a bracket off the spare wheel well.





I opted on this initial version not to fully seal it all off to allow rain and washing water to have somewhere to go.



I have removed the spare wheel and jack kit, so have lost front end weight, and the nose of the car feels very planted and would allow confident turn in at speeds over 70mph if that were legal.



The manometer data agrees with this feeling.

from the last news http://ift.tt/1p2vXDL

via IFTTT