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RPM PROJECT CAR

1: We started off y sending our Visner Engine Development billet manifold to the good folks at Nitrous Supply, who pre-assembled the intricate 16injector/16-port nitrous oxide system and assessed the maze of plumbing required to get it operational and performing its best.

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DEVIL’S IN THE DETAILS S story by

PART 25

>>Project aPocalypSe Horse gets set up for nitrous plumbing and some trick shifters are prepped for install

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ometimes in the world of project cars, you find that a lack of progress in one area means that you can turn your attention to other tasks. Unfortu-

may 2016 | RPM Magazine

Toby Brooks

nately, we thought this month would be THE month we might actually get some primer and maybe even some color on the car. Due to some unforeseen circumstances, that didn’t happen (a

photos by

Lloyd Chaudoin andTony Maples

tale for another time). However, we decided to focus instead on some tasks that we could do, and managed to get a good start on two items that have been on the list for a while.

First, our build will feature not one but two Nitrous Oxide Systems (NOS) Pro Fogger kits— one on the outer runners and another tucked away beneath the Visner Engine Development


2: Once the intake was shipped to Nitrous Supply for plumbing, install expert Lloyd Chaudoin discovered that the outer port foggers were going to interfere with the lower injectors. He decided to open up the original ports and re-machine them for better fit and improved performance. 3: Chaudoin loosely installed the octet of NOS annular discharge nozzles in the lower ports of the intake runners. Although it will be a tight fit, these orts can be used without any modifi ation.

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all-billet intake manifold. We are also working on a trick Billet Connection throttle body perimeter fogger plate with Ny-Trex solenoids that wasn’t quite ready for press time, but should be next month. Before that happened, though, we decided to sort out the plumbing on the 16-port, two-stage fogger system. After installing the 16 TRE fuel injectors on the billet rails and securing them, we discovered that the lower injectors in-

3 5 & 6: With original terfered with the outer set of fogger nozzles, making install ports plugged, Chaudoin then marked problematic. Initially thinkthe bung locations ing we might try to plumb the so that they could NOS systems ourselves, after be milled down to we discovered the issue in our the proper height intake, we decided to seek out to place the nozzles some professional assistance “deep enough” in the instead. We found it in Calirunner for optimal fornia-based Nitrous Supply. fl w, then placed the After speaking with intake back in the Nitrous Supply’s Mike Flynn, mill. The bung supwe learned that in addition to ports were also milled being a fully equipped supwith a smooth radius plier of virtually all nitrous for a clean look. oxide system components

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4: The upper nozzle location needed some fine tunin , since the angle of discharge was not steep enough to use our NOS annular nozzles (NS also sells a Straight Shooter nozzle for similar applications). At the same time, the angle of discharge matched the fuel injector bungs which wasn’t quite optimal for 90-degree units, either. As a result, Chaudoin decided to modify the orifi es so that a standard 90-degree nozzle would spray correctly into the intake while also allowing clearance for plumbing and threading the nozzle even with the fuel injectors installed. The trick was to do it without any welding, and his solution was pretty slick. He started by clamping the runners in a fi ture and machining the original orifi e out in the mill. The oversized holes were then bottom tapped to 7/16-20 threads and billet filler pl gs were installed. Once Loctited in place, everything was once again squared in the mill.

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RPM PROJECT CAR 7

7: With the new mounting locations established, it was time to drill and tap the bungs so that the nozzles could be installed. The angle of the runners relative to the mounting flanges ere measured and the angle of discharge was determined. The nozzles were moved back slightly and also tilted forward 10 degrees, providing the true 90-degree discharge angle desired for optimal performance.

9: The newlymodified mounting locations for the outer nozzles (top) now perfectly position a 90-degree fogger precisely where it needs to be, while the annular discharge nozzles in the underplenummounts (lower) were good to go out of the box.

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8: The plugs were staked to minimize the chance of turning before Chaudoin drilled and tapped the ports based off of the p eviouslydetermined measurements. in their own right, NS is one of the few suppliers who will install and flow components from other manufacturers, too. We securely wrapped up our intake and all components and promptly got them on the way to Huntington Beach for install. Once the components arrived, NS plumbing and install ace Lloyd Chaudoin analyzed the situation. We had originally selected NOS’s annular discharge nozzles—convenient because the “straight shooters” don’t require clocking in the bung in order to flow into the port correctly. However, Chaudoin quickly discovered a

clearance and spray angle issue in the outer system that needed to be addressed with some creative machine work. After milling the intake and installing eight billet port plugs, Chaudoin established the optimal mounting location and re-machined the intake to fit. Not only did this serve to improve flow by placing a new set of 90-degree fogger nozzles at right angles in the runners, it also solved the problem of the nozzles contacting the fuel injectors. The end result is an intake that is now ready for a wild 16-port plumbing system—but that task will wait for next month.

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10 & 11: The outer system’s nozzles now thread in place even with the injectors installed, and plumbing will be much easier. Meanwhile, the annular discharge nozzles under the plenum will be a tight fit but should work great once we get some hardline bent up and solenoids installed.

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RPM PROJECT CAR

13 13, 14, & 15: After we created a template on poster board to accommodate the Hurst QuarterStick, two NitroSticks, and the billet Lokar remote battery kill switch lever, we took it to 13 Sins, where fabricator Spencer Newman transferred the design over into a cut file using a CAD program. He then cut our parts on 13 Sins’ plasma table for a precise fit

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10 12: The idea was simple: match the look of our cool Hurst billet pistol-grip QuarterStick shifter with functional Hurst NitroSticks—actually intended for manual transmissions—to actuate our zoomie slide valves in order to create a pseudo-Lenco design that not only looked cool but served a purpose, too. The three stick-mounted switches were an added bonus, too.

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With the nitrous system well in hand in California, we turned our attention more locally to start building a trick but functional shifter mount and mechanism to command the Rossler 210 while also controlling the zoomie slide valves and remotely disconnecting the battery. For that, we opted to craft a custom mount from 1/8-inch steel thanks to 13 Sins Garage. Using our Hurst pistol-grip QuarterStick as a template, we loosely held a pair of similar

may 2016 | RPM Magazine

Hurst NitroSticks in place in Lenco style to get a feel for the bracket we needed. Adding in the functionality of a Lokar remote battery disconnect (we’ll cover install in a future issue, but it is a cool piece!), we sketched out the bracket we needed and took it to 13 Sins to be cut out on their CNC plasma table. 13 Sins Fabricator Spencer Newman took our paper templates and transferred the dimensions to a CAD drawing so that the CNC could do its thing

and carve up a sturdy one-piece bracket. While he was at it, he also created mounts for the zoomie slide valve linkage that will attach to the shifters in order to actuate the valves using a combination of rigid linkage and Morse cables.

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16: After a quick clean-up with a grinder, Newman took the cut base panel over and used a sheetmetal brake to create the desired shape. In order get the “Lenco look” we were after, we needed to do a little more fabrication work to the shaft f the shifter. Initially we thought it might be possible to heat the stick of the outermost shifter lever and lay it over the roughly 30 degrees away from midline to mimic the classic look of the bag-o-levers found in a Lenco-equipped ride. After proving futile, we opted instead to cut the

18: The completed piece matches the contour of the NitroStick perfectly and adds a stylish attachment point for the zoomie slide valve Heim joint actuator linkage and Morse cable.

17: With the base plate complete, Newman turned his attention to the shifter plates. Using our templates, he created a pair of 1/8-inch thick stylized steel mounts that will be affixed to one side of each of the NitroStick shafts. The forward mount will attach to a 1/4-inch heim joint to actuate the slide valves. After cutting them on the plasma CNC, he hit them with the grinder to dress the edges then mounted them to the shifters. shaft, position it as desired, and TIG weld it into position. Again 13 Sins came to our rescue, as Newman carved off a iece of 1/2-inch billet stock and carved up a lower portion before welding it to the main shaft. Coupled with the stylized steel heim mount, the end result is pretty darn cool... But not quite cool enough. With fabrication on the parts complete, we then turned our

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19: The outer shifter was modified o be angled away from the driver in classic Lenco style. Here, Newman positions the parts for TIG’ing.

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RPM PROJECT CAR attention to finishes, powder coating the brackets (see the tech piece in this issue!) and ceramic coating or anodizing the shifters themselves. Although we didn’t quite finish the entire assembled piece prior to press time, it should be completed soon and will add both form and function to our street-rod-meetspro-mod (“Street Mod?”) interior we are planning. With our setback in paint and body,

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20 & 21: Newman fi ed up the Miller TIG welder and laid down several passes to complete the outer shifter. The units were then drilled to accept bronze bushings and mocked together in the fabricated mount using 1/4inch steel shaft and a series of thrust washers. We’ll send them off for some cus om CNC work after either ceramic coating or anodizing them, but the end result is going to be killer!

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we’ve scrapped plans of having the car complete in time for the Street Machine Nationals, but we are reasonably sure we can get it plumbed, wired, and running and get the entire body into primer in time for the show for a pre-debut, then complete everything in time for a full debut in time for the 2016 SEMA and PRI shows. It’s gonna be tough, but we’re hoping it will be running soon. Stay tuned!

SERVICES Nitrous Supply www.nitroussupply.com 714.373.1986

13 Sins Garage www.13sins.com 806.683.9076

SOURCES Nitrous Oxide Systems www.holley.com/brands/nos 866.464.6553

Visner Engine Development www.visnerengine.com 616.726.6600

Hurst Shifters www.hurst-shifters.com 707.544.4761

Lokar Motorsports www.lokar.com 877.469.7440

1605 part 25 devils in the details  

Part 25 - Devils in the Details

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