My WAI

[GasSavers_maximilian]

I had been using the area of my 3" duct to compute how much the shield needed to be moved forward, but that is an overestimate, so I measured the kidney shaped duct from the picture I took. It came out to basically 50% as much, so while the shield does still need to moved with spacers, they can be a lot smaller than the initial guess. Around 3/16" or so is my estimate. This lower area requirement means I can make the wide end of the adapter shorter, giving more clearance to the plastic engine cover, which was something I worried about. Going into town today, so I can see if anyone carries the metric bolts I need.

Scratch that, the existing bolts are long enough for 3/16" spacers. Nice.

[GasSavers_maximilian]

Trying to angle in a manifold shield with nine stacked washers held on by three hard drive magnets in very close proximity to large pieces of iron and steel.

What could go wrong?

[GasSavers_maximilian]

Yep, the dipstick tube and manifold would invariably pull off one of the magnets enough to spill the washers. Also, having to center the manifold shield without being able to look through the holes was a lot tougher than I expected. I finally used a bit of Elmer's glue to make the washers into a stack and then glued them to the manifold, being careful not to get glue in the threads. Worked like a charm. After I run for a bit I'll make sure the glue burning off hasn't created gaps, loosening them. There is now a respectable gap at the top of the manifold I can work with, but it's not obviously modified for warranty purposes. The O2 sensor not being centered in the hole anymore is the only real clue.

[GasSavers_BEEF]

these magnets you speak of. how strong are they and may I offer an alternative?

if you have an old hard drive (or access to one) they have stupid strong magnets in them that might be helpful.

though it sounds like you have gotten most of this figured out. let us know when you have results. how are things looking and are you enjoying the scangauge?

[GasSavers_maximilian]

The glue got the job done. The magnets were hard drive ones I got from a surplus place. Stupid strong is right! magnets were just the wrong way to approach it, since I really had to squeeze the shield around things to guide it over the O2 sensor. Brought it too close to other metal bits.

The SG2 is great, although it isn't calibrated yet. Once I do that I'm going to take mpg readouts on that reasonably level stretch in 5 mph increments from 30 to 65. Be a neat graph.

I toyed with mounting it in with my gauges, but it's good enough in glare (and there's a lot in that space already, especially when I have my TomTom along) that I'm going with a center console mount. By chance it fits in the default holder very well. I had the LOD gauge selected this morning and it showed 25 when I was coasting in neutral (engine on). That seems weird.

[theholycow]

A similar glue trick is hammering nails too high to reach. A dab of silicone holds the nail to the hammer (you don't have to wait for it to set), and you give it one good whack to get it started.

[GasSavers_maximilian]

That's a great idea! I have this book called Tricks of the Trades that has all sorts of neat tips like that. Don't think it has that one though.

[GasSavers_maximilian]

OK, got the adapter made. This gets the air out from the top of the shield, so it stays flat for a couple inches then funnels to a 2" square tube. This can fit inside my 3" duct and has enough flow area. I changed the design from the drawing to have the hose hook to the back. I think this will work out, but if not I can add a 90" bend to it easily enough later. I tried to make the halves interlock as much as possible, but still needed eight rivets to keep things stiff. Wish my spot welder was working!

Here are the two pieces before assembly.



Assembled, bottom view.



Assembled, side view. Note the drilling screw up.



Assembled, back view.



Here's a close up of one of the tabs that will hold it in place. I'll just bend it backwards to hook onto the manifold shield.



I need to design the air bypass, which will go on the top, since it has the largest flat area. This is the most complicated sheet metal part I've ever made and the fit could be a little better, but I'm just an amateur. I'll seal it with some high temperature mastic I had left over from my chimney installation.

[GasSavers_BEEF]

not to be critical but...

is the square footage (square inchage maybe) of both openings of that the same?

I am not that great at eye balling it but you don't want a restriction there. I do like the construction as long as it isn't a restriction. also, how do those figures lign up with the square footage (square inchage) of the first bean shaped piece?

[GasSavers_maximilian]

Originally Posted by BEEF

not to be critical but...
is the square footage (square inchage maybe) of both openings of that the same?

This definitely counts as constructive, so no worries! Not quite the same, but they're both above the minimum. The square end is 2"x2" and the slot end is .5" x 9". I did that intentionally because there are a few obstructions under the shield. The bean was 3.53 sq in, so I have some safety margin. Thanks for the sanity check.