Flares.....

[Darren65]

..the advantage of having CAD scans of the both inside and out of the end caps (rather than just a mould casting of the outside) is of course that you can replicate the inside exactly....



...another piece of the jigsaw is the oil pressure relief valve built into the cooler. These are a fairly simple item consisting of the drain plug, spring and ball bearing. Fortunately it helps to have friends who can send photos and all dimensions of an original and all these items, including the spring with the correct wire thickness, number of coils and operating pressure etc are currently being fabricated.....



...

[Darren65]

....alas with any project there is a degree of compromise and in this case, as a few no doubt will have noted, it's the core.

Originally a bar and plate item these days they are generally replaced with a tube and fin design when coolers get re-cored.....virtually impossible to get close to the original design, we looked at a number of possibilities and could have had a bar and plate core fabricated although this would have been to different dimensions and not an exact recreation so therefore not an option.....it was suggested that these could be manufactured in China which is a big producer however I was strongly advised against this due to the gauge of the aluminium being thicker which would have hindered performance, the quality of recycled aluminium generally used in China being to a lower specification and the weight of the cores which would have been far heavier. I don't doubt that there are manufacturers in China that could produce a core to a suitable standard and quality but go find them and for me it's not worth the risk!....

....ultimately this cooler needs to be of the highest quality, be tested to 10 Bar and perform to motorsport standards, I also wanted it to be to the exact dimensions of an original and therefore I accepted the professional advice and went with a proven supplier. Fabrication will soon start as soon as the end caps are machined .....



Cheers,

[Jens]

Brilliant werk, Darren.

[Darren65]

Thanks Jens, all being well I should be able to show the finished cooler in 6-8 weeks…..

….hopefully mounted on a shiny blue shell!

Cheers,

[Darren65]

Loaded for a trip to the Bodyshop.....



....next stop Meh-He-co!

[patrick911]

Awesome Darren, that's been a long time coming. Must be very rewarding to get to this stage.
Looking forward to see the shell in beautiful Mexico blue!

[Darren65]

Awesome Darren, that's been a long time coming. Must be very rewarding to get to this stage.
Looking forward to see the shell in beautiful Mexico blue!

.....thanks Patrick, it has indeed by. long time coming!



Seam sealed to death and ready for paint....







....

[Darren65]

....and finally.....COLOUR!....











....

[Darren65]

......sorry....I meant COLOR

[Darren65]

....one day soon!



Cheers,