10 replies to this topic

[rik]

Hi Long time since I've posted but have still been lurking from time to time. I had made a new heater box out of ally last year since the fezzasus one is no longer available and I had missed out on them. I was planning to convert my design into something which could be 3d printed so that I could reproduce them easily or even make the design open source. However I've now seen the other box being developed, so I'd like to know if people would be interested in an another alternative one. The design uses an all alu heat exchanger approx 2x the size of the original one, sourced from a Daewoo which are readily available new and reasonably priced. Along with a resistor pack from a Kia. It is housed in a box which has a flap design and passes the air through the radiator twice (cool side to warm side like dual pass charge cooler). Flap uses proper bearings top and bottom. Along with a slot for an air filter on the front. Mounted with plastic brackets front and back. Fan would be the original one, but I could provide a clone housing since they break too. It would be plug and play with the original wiring and cable control. The 3d printed parts would be made of some of the new copolyester filament which have very high temperature resistance I have been working on drawing the parts in cad but it's not finished yet... Should I continue - is there interest? Cheers Richard

[Strugs]

Really good effort, but - with the T7 one seemingly imminent - I fear a smidge late..

[H1 HWK]

Hi Rich,

 

Sounds like you've done a fair bit of research to make a replacement hybrid from parts already existing in the market, which is great in terms of low volume & availability.

Might be good to put a guide price down for the finished version to give people the options of a totally bespoke version vs your hybrid?

 

Also have you installed one to see how well it works compared to the standard item, to give people an idea of the upgraded performance?

 

Good luck.

 

 

[Aerodynamic]

Thea this could be interesting, line Will probably breake down soon. Id like to know the size and guide price. Br, Per

[rik]

Hello I ran the pricing through excel and it came out at just under £300 - that's with full price for everything... Pretty sure we could find the radiator, resistor and hoses for a bulk discount, could easily knock off £40-60, maybe more. As for performance, the alloy one I made worked but I didn't do any temperature analysis or anything. Car's off the road now so I'd find it difficult to test the printed version, so I would perhaps give one or two out to be tested by reputable members. Hope to have something ready to be printed next week so I will post a photo Thanks

[Paulus H]

Welll done, I am suprised you are using the original fan though. I have always thought that by the time the air reaches the dash area max speed on the std fan was like minimum speed on a normal car.

 

Kindly, Paul

[rik]

Hi

I have made quite a bit of progress now... still a few minor tweaks to make to the box and then I'll do the mounting brackets and cable holder/mover

 

@paul I think the original fan is fairly decent, I always thought that it was just the original ducting which was prone to leaking pressure. I have been thinking on how to integrate a better housing for it but I'm not sure yet.

The motor and impeller are originally from a land rover defender and there is a good supply of new ones  https://www.britishp...r-motor-RTC4201

 

Assembled box and fan:

The radiator connectors will need to be shortened and re-swaged lower down

 

 

Fan and side removed:

 

Flap positioned for cold air:

 

Flap positioned for hot air:
You can't see it here but the radiator is the full width of the box, so air goes through the rad and then back out again into the fan

 

Filter removal:

 

Fits in the space with a little room to spare, but my battery terminals aren't standard - what are the standard ones like, do they stick out further?

 

Edited by rik, 09 May 2017 - 09:36 PM.

['Buchos']

  Fits in the space with a little room to spare, but my battery terminals aren't standard - what are the standard ones like, do they stick out further?  

My battery terminals don't stick out any further than the battery itself, so I think you're fine for space. I'm one of the few who dont need a heater but I really really want a 3d printer, some great stuff can be achieved there

[glitch]

I recently fitted a battery isolator. It was tight to get in there, with it in place your heater box would not fit as the isolator sticks out to the side.

[rik]

Thanks Buchos & glitch

Decided to go with a 3d design of the fan housing, should free up a precious few mm.

Started the first test print of it this morning

 

[rik]

Dropped off the first one with ChubbyChiper at Phoenix motorsport on Monday. Few pics of it below

Looking for a LHD member who wants a trial unit as well