MONTE CARLO "COPO" Monte Carlo SS - Turbosaurus Build (Swinging Dick Racing's c*ck got bent... she bounced a little too high & hard, & came down awkwardly)

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And this is why I built a 4" downpipe and exhaust system:


People who claim to have problems with a $150 turbo applied equally cheap or limited approaches to everything else influencing it's performance (into and out of it, hot side and cold side).
 
Bigger is better in terms of downpipe fer shur
 
More weldy weldy and more scrubby scrubby.

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Made some templates and transferred them to some sheet ready for Senior Plasma Cuttero.

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After much deliberation I have decided to fully box the frame to the inside. This is as opposed to running a half pipe, parallel rails (ie a full pipe), or doing a partial boxing. It basically boils down to strength and a stock-like appearance.

After I get these cut out and burned in I can start on the reinforcements, and doing the UCA relocation brackets... and replacing the wheel tubs... and continuing the bodywork... and...

bill hader crying GIF by IFC
 
So all that wasn't fully welded from GM I take it?

Only on the other side, and rather poorly.

Once the frame is cut out for the full notch many of those factory welds will be gone - so they had to be replaced or risk a catastrophic failure.
 
Busted out the plasma cutter and went to town. Worked really well all things considered given I free-handed the whole batch. Lots of scrap left over to teach the Mrs. with.

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It made this really fine dust. Screw you, I found it interesting!

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Knocked the slag off, and went over the edges with a grinder and a flap disc.

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Not bad for an offshore box.
 
We know full well that Instagram welders cannot hang in the realm of a simply functional weld, or even grasp how to deal with a less than perfect scenario. So when working on old rusty cars it is good to know what will get the job done:


The drive roll tension is a pretty interesting point I never considered, I just set the tension per the instructions inside the lid.

Remember: Form follows function.
 
Busted out the plasma cutter and went to town. Worked really well all things considered given I free-handed the whole batch. Lots of scrap left over to teach the Mrs. with.

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It made this really fine dust. Screw you, I found it interesting!

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Knocked the slag off, and went over the edges with a grinder and a flap disc.

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Not bad for an offshore box.
Get some ferrofluid and have some fun with the kids- magnets!
 
I bought a roll of flux core back in 2012 and have yet to deplete it. Never had any structural issues with it either. Here is me zapping the ends from another frame to make mine whole again on the dually.

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