Front End Redux (FD)
 

I wanted to redo the front end of the car for several reasons. First was to re-mount a radiator I was having leak issues with. Second was to simplify working on the car, and third was to drop some weight.

I made some updates to the fuse/relays in the front of the car. I got rid of all the factory fuse boxes and relays. Now I'm using this piece from Blue Sea Systems. Its very nice. This pic makes it very obvious that I'm not going to be running pop up headlights anymore. I don't have a replacment yet, but I've got some prototype test pieces in the works (LED). Location will likely be in the indicator/turn signal area. More to come on that when I make some real progress.
IMG_7606.jpg | Flickr - Photo Sharing! IMG_7606.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

The next thing to do was to open up some more space, to fit the over the radiator intake I wanted to do. The factory front crossmember was in the way of my filter setup so it had to go. I took the opportunity to stiffen up the chassis a bit too. I increased the size of the front crossmember pretty significantly, without adding any weight. This first pic really shows all the space this opened up. This winter I also bought a HVLP spray gun and proper air dryer/filter. Results are amazing! During the fabrication of this I made a dimple die and put a ton of 2" dimples in this piece.
IMG_7609.jpg | Flickr - Photo Sharing! IMG_7609.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

IMG_7607.jpg | Flickr - Photo Sharing! IMG_7607.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

Then I added a whole lot of holes in the fiberglass bumper support to lighten it up.
IMG_7616.jpg | Flickr - Photo Sharing! IMG_7616.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

Here you can see how tight the cross member I made fits into the fiberglass bumper cover.
IMG_7622.jpg | Flickr - Photo Sharing! IMG_7622.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

The power steering cooler is moving from in front of the radiator to the side opening (where the stock oil cooler was). Here is the mounting bracket.
IMG_7626.jpg | Flickr - Photo Sharing! IMG_7626.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

I was tired of my radiator leaking so I bought a new one. This is a C&R custom. 27.5" wide, 15" tall, 3" thick. Its a double pass, two row. I've got 2 11" spal fans mounted on the shroud. I made the shroud with a cutout for the crank pulley. Its very tight to the engine. I used silicone bulb seals to seal the shroud on the sides.
IMG_7642.jpg | Flickr - Photo Sharing! IMG_7642.jpg | Flickr - Photo Sharing! by Kevin_Doe, on Flickr

Then to prevent putting any chassis flex into the radiator I built an all aluminum radiator subframe. I also mounted the new oil cooler to it. This cooler is MASSIVE. Extra details went into this piece to keep it lightweight.
IMG_7646.jpg | Flickr - Photo Sharing!IMG_7646.jpg by Kevin_Doe, on Flickr

IMG_7654.jpg | Flickr - Photo Sharing!IMG_7654.jpg by Kevin_Doe, on Flickr

Mounted my mocal oil stat to the subframe.
IMG_7657.jpg | Flickr - Photo Sharing!IMG_7657.jpg by Kevin_Doe, on Flickr

Mounted in the car. All the orange is 1/4" silicone foam. The radiator will simply rest on it.
IMG_7663.jpg | Flickr - Photo Sharing!IMG_7663.jpg by Kevin_Doe, on Flickr

Installed in the car. The power steering cooler is in too.
IMG_7664.jpg | Flickr - Photo Sharing!IMG_7664.jpg by Kevin_Doe, on Flickr

Radiator installed, with hold down brackets. 1/4" foam on those too.
IMG_7674.jpg | Flickr - Photo Sharing!IMG_7674.jpg by Kevin_Doe, on Flickr

IMG_7675.jpg | Flickr - Photo Sharing!IMG_7675.jpg by Kevin_Doe, on Flickr

The radiator is all sealed up on the bottom and sides from the subframe and foam. The top will be sealed by this set of weather stripping. The part is the air filter shroud.
IMG_7677.jpg | Flickr - Photo Sharing!IMG_7677.jpg by Kevin_Doe, on Flickr

IMG_7682.jpg | Flickr - Photo Sharing!IMG_7682.jpg by Kevin_Doe, on Flickr

IMG_7688.jpg | Flickr - Photo Sharing!IMG_7688.jpg by Kevin_Doe, on Flickr

Awesome work.

Wow thats a pretty big rotary engine :nod:

It gets the job done at 487 whp, and 435 ft-lbs. Over 350 ft-lbs from 3000 to 7000. Over 400 ft-lbs from 4000 to 6000.

Any significant changes in temperature behavior yet? Looks awesome.

No changes in temp. I didn't have a cooling issue before though, so I wasn't expecting any differences.

Amazing work.