Josh's City Goblin - 10 XFE Donor

[jirwin]

@Traé yes is does function. I will keep that in mind, thank you.

Started a different thread for the truck: https://dfkitcar.com/forum/index.php?threads/tow-rig-2003-silverado-1500hd-quadrasteer.4989/

Ok! Back on topic! I've made a little progress on the heat exchanger side pods in between other projects.

The sidepod itself I have very crudely mocked up in CAD, and have cut it out on my CNC. Obviously it doesn't have full walls in the picture, this was just testing the top and bottom fitment. I need to update a few dimensions, make it out of 1" foam board, reinforce it a bit, then lay fiberglass. Slowly but surely making progress!

 

[Desert Sasqwatch]

Will you be adding a fan to the heat exchanger? There is plenty of room inside the side pod from your mockup. Maybe a small fan (6 inch) over 1/2 of the face, leaving the other 1/2 exposed for natural airflow while moving - that way you can still get some cooling when stopped or moving in slow traffic?

 

[jirwin]

Yep, thats exactly the plan. I have 7" fans that will go in there. They'roughly 2.5" thick, so there's plenty of room to feed them air. Plus it will guard the fins a bit

 

[Robinjo]

Why don't you just go ahead and make 3 or 4 of those once you are happy with it out of carbon fiber.....

 

[jirwin]

Let see how effective it is and how good it looks first lol

 

[Robinjo]

 

[jirwin]

V2. I think I'm just going to fiberglass this one just to work out the kinks in the process. I've never fiberglassed anything before so I'm bound to mess something up and learn. Will probably have to wait until this weekend as I know I want ventilation and its currently 27F outside.

 

[Chris_WNC]

I want to try to glass something one of these days too. Keep us updated on your progress. Lessons learned and such.

 

[Desert Sasqwatch]

Caution- use epoxy resin when fiberglass on foam. The 'bondo' polyester resin will eat the foam if it is not coated first - latex paint could be used as a coating. The epoxy resin is typically available from boating or aircraft suppliers.

 

[jirwin]

I plan on covering it in mold release film so that shouldn't be a concern

 

[Desert Sasqwatch]

@Chris_WNC is a fiberglassing newbie, my comment was mainly for his info.

 

[jirwin]

Got the sidepod moulds assembled. CNC worked with a few minor hiccups. I think the moulds turned out great. The actual glassing I underestimated. I need way more resin and patience. Living right by the Bay, theres a lot of local fiberglass places for boats. I'm going to just see what they would charge to glass my moulds tomorrow. If its too much, I'll buy more resin and finish the fight.

 

[jirwin]

Well, I spend a few hours trying to fiberglass yesterday. This is hard lol. The amount of time it takes to get right really is difficult. They have the right shape generally. I used 4 inch wide rolls of fiberglass chop in (mostly) criss crossing pattern. It was very time consuming and I definitely did it in a messier way than needed. I had originally bought woven fiberglass but decided to use the matt as I thought it would be easier to apply around the 3D corners. They turned out... ok. The general shape is there. They are a little bit flexible on the straight sections. I think I'm going to try finish the 3D model and unwrap it so I can cut it the woven fiberglass into the perfect shape. Then I can apply it in a couple extra layers on the outter surface. I will able be able to add some extra fiberglass on the inner corners for more strength.

 

[Desert Sasqwatch]

Fiberglassing is as much art as technique. Getting it right is more trial and error as knowing what it should look like versus what the finished product turns out. Nice thing about fiberglass is the 'bad' parts can be removed and second (and third) tries can be added. I think it's turning out fine and with some 'massaging' will be good looking pieces. The pros make it look easy, but they also have years of experience.

 

[ah.b.normal]

Well, I spend a few hours trying to fiberglass yesterday. This is hard lol. The amount of time it takes to get right really is difficult. They have the right shape generally. I used 4 inch wide rolls of fiberglass chop in (mostly) criss crossing pattern. It was very time consuming and I definitely did it in a messier way than needed. I had originally bought woven fiberglass but decided to use the matt as I thought it would be easier to apply around the 3D corners. They turned out... ok. The general shape is there. They are a little bit flexible on the straight sections. I think I'm going to try finish the 3D model and unwrap it so I can cut it the woven fiberglass into the perfect shape. Then I can apply it in a couple extra layers on the outter surface. I will able be able to add some extra fiberglass on the inner corners for more strength.

View attachment 47129

View attachment 47130

If you need more rigidity across long flat areas you could glue long 1/2" thick (or what ever the thickness of your pink insulation is)X1" or 2" wide strips of that foam and then glass over them, they will cause excellent stiffening tubes.

 

[jirwin]

Got impatient and installed and plumbed the new heat exchangers. They shouldn't really get dinged up since they are sideways (past sideways really, facing backward). Hoping to find time before the weekend to add more layers to the fiberglass and see where that gets me.

 

[jirwin]

Also got V2 of the exhaust tacked and fitted. Needs s light tweak, but its pretty much where I want it. The 180 I got from ZZP is a bit bigger than I wanted, but it'll work just fine. Might have it laid down more so it doesn't come as high.

 

[jirwin]

I cut the sidepanels and tested the heat exchangers yesterday. I'm a bit underwhelmed if I'm being honest. I don't have the side pods on yet because I just haven't had the time/patience to dedicate to it. Regardless, in testing it seems it recovers fast but doesn't stay low? I'm thinking this might be due to coolant capacity over cooling capacity. I didn't beat on it too much, but did a few 2 to 3 pulls. Only halfway thru 3 really. IAT2's were already spiking to 120F by then. ~70F outside temp. I really just need to take it out and do a full 1/8th mile pull and see where it puts me. When cruising, IAT2s stayed below 95F. I turned off the fans while driving, and let it creep to 105F. Turned them back on and within 5-10 seconds they were back to 95F. So its definitely working but I'm not sure its enough to keep up when under WOT.

 

[jirwin]

Well, maybe I'm just being paranoid after all. Sent something to ZZP about 120F IAT2's and this was the response:

 

[Rauq]

For what it's worth a GMS2 LSJ tune pulls 3° of timing at 140°F. No timing pulled at 120°F. You're good. It does sound like normal LSJ intercooling where the coolest temps are just cruising, with higher temps while sitting still more or making power, and temps that drop somewhat quicker after idling than after making power.