Progress (3)
January 2019
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Trial fit - that's my son. Tiny car!
Same son, 12 years earlier!
My tig welding is getting better but still needs a lot of work! Ok for this though.
Headlight brackets.
Fenders mounted, lights mounted. Rear are fastened with Dzus fasteners, front use fully adjustable brackets, in case I change wheels or tires.
The stock Toyota TVIS intake is NOT going to clear the hood. Plus, the throttle body at the front will it the front cowl. Problem. BTW, the intake TVIS system has two runners for each cylinder. At low RPM only one opens...improves low speed torque. Engine would run without it but I'm leaving it in.
The answer to the clearance problem is to take a TVIS manifold from a FWD Corolla, cut it and weld to make it fit under the hood.
modified FWD manifold now clears everything nicely
after cutting in half I had to go back, add filler , regrind on the belt sander to get the two halves of the manifold to fit together. I ground the inside of the mating surfaces to make as smooth inside and outside curve.
with a die grinder I cut a groove to weld into for full penetration
and then tig welded it back together. Its a bit fugly but it worked. Hey, welding castings is not easy!
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