My ongoing Turbobaja build

turbobaja · Post by **turbobaja** » Mon Aug 04, 2008 8:04 pm

Yes, sometimes it hurts.......my wallet. Some of us are slaves to our cars.

Seriously, though, adding a bunch of volume to a stock fuel tank is cake. Compaired to some of the structural modifications I've seen other people do on here. Not to mention, some of you guys are actually driving around from time to time in your bajas, buggies, and such. God, what's that like? I can't wait till it's back on the road.

Thanks for all the kudos. I enjoy sharing my project with you STF'rs. Thank you for all the ideas and techniques I've been able to scam on myself. Maybe some of you might consider trying some of the stuff I've done and learn from me too.

Karl

turbobaja · Post by **turbobaja** » Fri Sep 05, 2008 7:38 pm

Finally got the tank welded up and pres. tested good. Pretty supprising considering how some of the welds turned out

. Also finished plumbing the complete fuel system in -6 AN.

I also got all the makings for a 4-port water/meth injection with progressive controller from Snow Performance. Jets are from Coolingmist.com and flow 50 cc/m, one in each intake runner. Probably going to tap them on the inboard side just below the vac/boost sensor ports.

Also got one of those cheap azz 16 ton pipe benders from Northern Tool. Bends are HORRIBLE so far. I reshaped the pathetic die to fit the pipe, gotta try some sand next. I only need some really slight bends to clear the back seat for some cage enforcements. I guess I got a 16 ton press if nothing else.

Karl

Post by **Leatherneck** » Fri Sep 05, 2008 8:06 pm

Sweettt as usual,like the use of the stock tank with mods of course. Pack the sand in real good and it should help your bends, use heat make it even better just make sure sand is super super dry.

turbobaja · Post by **turbobaja** » Fri Sep 05, 2008 8:20 pm

Thanks Leatherneck. I'm trying to bend .120" wall 1.5" DOM tubing. I figured the thicker wall would help keep its shape a little better, but no such luck. Looks like I'll be packing some sand and welding caps on the ends. I've been lucky enough to have prebent pieces from the class 11 kit for odds and ends left over. All my additions so far have been straight pieces. I've got to tie the rear bumper into the cage better and add some beef to the rear bumper itself for towing, etc. Time to learn how to bend tubing

Karl

Post by **Leatherneck** » Fri Sep 05, 2008 8:24 pm

Might save you some time but when I bent mine I just put demim over the end and secured with a hose clamp. Should not need to weld it, try without first.

klrskies · Post by **klrskies** » Mon Sep 08, 2008 2:09 am

I've enjoyed watching your excellent build progress. Thanks for shareing it. Just want to say your efforts are much appreciated. You display amazing creativity and craftsmanship!
best regards,
Ken

turbobaja · Post by **turbobaja** » Mon Sep 08, 2008 6:26 am

Thanks a lot Ken. Those are very kind and encouraging words.

I did manage to get some decent bends over the weekend. Packed pipe with sand and capped with some canvas cloth and hose clamps like Leatherneck suggested. Worked much better. I think 90 deg bends are out of the question with this POS, BUT 45s are doable. Haven't tried heat yet. We'll see.

Karl

turbobaja · Post by **turbobaja** » Fri Sep 12, 2008 7:43 am

Got the tank sealed up an tested volume and gauge travel.

Kind of an unusual fuel gauge to see in the States, but it reads pretty accurate. I had to modify the float arm a bit and clock the sensor 2 screw holes clockwise in the tank to clear the pump. This guage actually reads more accurately now than it did with the stock size tank back when I used to drive the thing around. I used to dissregaurd the readings and just treat it like a normal gauge. Straight up was half tank instead of nearly on RES as the gauge shows. Now its reads as follows:

1 gallon is just over E.

2 gallons is at the top of the RES section.

6.5 gallons is 1/2 tank.

11.5 reads at the full mark.

14 gallons is the end of the gauge travel (needle covering the F) and leaves me with about .5" of air in the tank. With the fill neck on I figure this is where the gas pump will shut me off.

Tank is 25lbs empty. 140lbs full of H2O, and should be just over 110lbs full of gas. This gives me about 85lbs of weight fluctuation on the front end between full and totally empty.

Turned out pretty good.

Karl

panel · Post by **panel** » Fri Sep 12, 2008 6:18 pm

Any baffles or foam in there

ToRy 70 · Post by **ToRy 70** » Sat Sep 13, 2008 9:25 am

This is such a cool project, Karl. I love fabrication pics, and this will be one capable baja!

I too fell victim to the el cheapo pipe bender, except I was dumb enough to try and bend 0.090 chromoly! I had it packed with sand and everything. It looked ok while I was bending it ( a 45), but when I pulled it out it was crimped as a mother.

Lesson learned. Luckily I only bent a small piece of material, I have enough left to send it to the local rollcage shop.

turbobaja · Post by **turbobaja** » Sat Sep 13, 2008 10:52 am

Thanks ToRy. I want a quality mandrel bender now more than I did before I got this cheap piece of junk. Lesson learned for sure.

Panel, I share your concern. I deciede to weld it shut without baffles or faom. Just the small wall behind fuel pump that will hopefully keep from starving out on accelleration and hills.

As far as 'slosh control', I got nothing. Someone did suggest making a foam insert that leaves room for the pump and level sender, but I was worried about not getting as much volume in the tank. Baffles would have been a good choice. The truth is, I didn't do any research on this stuff. I just wing'd it.

Some times I think I know what I'm doing, when I really don't have a freakin' clue. I'll slice this tank open and baffle/foam it up if that's the right thing to do. Tell me what you guys think. Am I playing with fire??

Karl

turbobaja · Post by **turbobaja** » Sun Sep 21, 2008 8:53 pm

Alright, I guess nobody thinks baffles or foam is completely necessary. I'm going to paint it up as is.

I lined all the boost pipes, breather tank, vac/boost can and intake pipe with the same sealer I used in the tank. Then I POR 15'd the outsides. I finally have some parts that I can call DONE.

I also got a big box of aluminum pieces blasted and ready for powdercoating.

Once the gas tank is painted I'm going to put off the powder coating till the garage is a little cleaner, and I'm in paint mode.

Next: make use of this bender and finish up on some structural parts.

Karl

64bug · Post by **64bug** » Sun Sep 21, 2008 9:37 pm

This is a purely amazing build. Fantastic work man!

turbobaja · Post by **turbobaja** » Mon Sep 22, 2008 6:19 am

Thanks Robbie. I've been admiring your project for a couple years now it seems. Maybe it's something about the Northwest that makes buiding a car take twice as long as it should.

Looks like you've beat me to the drivable stage. We'll have to get together and burn some rubber in the future.

Karl

64bug · Post by **64bug** » Mon Sep 22, 2008 8:16 am

Haha ya its taking froever, but you really cant rush it. And i've only been in first gear so... Im not too much further... Keep up the great work.