1998 Jaguar XJR Cooling Fan Conversion

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1998 Jaguar XJR Cooling Fan Conversion

The other day we started on a 3d printing project for a customer’s 1998 Jaguar XJR Cooling Fan Conversion. One of the customer’s radiator cooling fans stopped working and the engine started to overheat. The fan assembly from Jaguar were quoted between $1100 and $1400 (for 2 fans and the shroud) We told the customer that there was a second option. The other option was to convert the fans over to brushless slimline style cooling fans.

The Process

I took about 20 measurements and traced the mounting holes. Then I scanned the tracings on my flatbed scanner. After that, I digitized the files and imported them into Fusion 360. After a few hours, the CAD files were done and it was ready to print. I stayed up until about 3am, making sure the first bracket was printing ok. It wasn’t. Some of the settings needed tweaked. I changed the settings and hit print again, praying that when I woke up the print would be good.

When I woke up 3 hours later the print was almost done and looked really nice. When that was done I removed it from the build plate. Then, I hit print again. I went into the shop to start modifying the shroud.

One of my techs ended up taking the motor apart and we extracted the OEM harness connectors. I wired and loomed that electrical connector to the fan harness. Furthermore, this made for a really nice, cohesive OEM looking connection.

Fitment

This bracket will fit the following Jaguars:

  • Vanden Plas – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003
  • XJ6 – 1993, 1994, 1995, 1996, & 1997
  • XJ8 – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003
  • XJR – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003

How was it made?

The XJR Cooling Fan Conversion is printed on a highly modified AnyCubic Kobra Max 3d printer with Priline Polycarbonate CF. For example, here are the A-Z photos of how it was done, and how it all turned out.

Gallery

Front – Fans and shroud disassembled
Rear – Fans and shroud disassembled
Bolt pattern on the back of the fan shroud.
Measurements, tracings and templates we made of the shroud and fan motor mounts.
Digitizing the measurements, tracings and templates.
Drafting the digitized measurements, tracings and templates.
Bottom Angle
Top Angle
Minor modification of the slimline fans. Left side is modified.
Another shot of the minor modification of the slimline fans.. Left side is modified.
Printed bracket mocked up for some minor trimming.
Marks for trimming shroud for fitting the bracket.
How we clearanced the shroud for the bracket.
One last modification. This had a piece sticking up about 3/4″ / 20mm that has to be removed.
Test fit. Check.
Fitting the brackets, both sides
Mounting the fans.
Fans installed. Hindsight, I should have wired the plugs first.
Install – Back side
Quarter shot of the fans installed
OEM fan connectors wired and loomed
Upper fan close up of the OEM fan connector.
Lower fan close up of the OEM fan connector.
Another lower fan shot.
One last upper fan connector close up.
Front side – Complete
Ready for install
Rear – Ready for install
Side shot rear – ready for install
Front side shot – ready for install
Installed
Upper shot installed with much more room to service belts, etc.

Question / Contact Meister Werks

For more information on how to get your XJR Cooling Fan Conversion installed, please call 425-254-0627. You can also contact us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

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European BMW 635csi

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1980 Euro Spec BMW 635csi M90

Today we finish a engine for a customer’s 1980 BMW E24 635csi. Here are the specs on this build.

Engine:

M90 Euro Spec
King Bearings
CP Forged Pistons 10:1 Flat Top

Head:

Stage 3 Port & Polished
Schrick Cams
Ireland Engineering Valve Spring, Rockers, & Guides
ARP Everything.

Powder Coat:

BMW Silver: Intake, brackets, oil pan, intake manifold & plenums, coolant flanges, etc…

Stay tuned to see this 635csi, subframe repair, steering, suspension, exhaust and custom header install.

 

1985 Article about the BMW 635csi

In many ways, the 635CSi is a superlative car. It produces prodigious speed thanks to its new 3.5-liter engine. The 635csi exhibits much better handling than BMW’s early 6-series coupes. It is put together ,vith rare care. Its ergonomics are generally excellent. And now it has Bosch ABS anti-lock braking equipment for help during emergency stops. All told, the 635CSi is a very accomplished piece of work.

Still, we’re talking 3.5-liter, high-rev­ving. seven-league boots here. BMW has punched out the 3.2-liter bore from 89 to 92mm, and the torque has increased from 195 to 214 pounds-feet. This single overhead-cam six is old. but it remains atop the pack in basic design. Its aluminum hen1i head is fed by Bosch Motronic fuel injection. Crossflow intake and exhaust ports handle the breathing. and a new, adaptive Lambda-sensor control sets the fuel-air mixture more precisely through a ,vider range of operation. ·ro allow maximum spark advance at all times, BMW has not yet resorted to a knock sensor, and the 3.5-liter motor compression ratio remains a impressive 10:1. The added dis­placement has bumped up, the horsepower only from 181 to well over 250hp. However, it is tuned instead for midrange response, the big six’s power peaks at 5400 rpm, 600 rpm earlier than in the 3.2-liter. A 3.45:1 final-drive replaces the 633’s taller 3.25 gear, boosting the throttle response throughout the rpm range. but a rev limiter clips the power smartly at 6200 rpm.

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Wrapping up the 1984 Porsche 928S Project

Some of the photos after everything was finished up on our customer’s Germany market 1984 Porsche 928S, which included:

  • Complete Transmission Rebuild.
  • 100% Genuine OEM exhaust replacement.
  • Complete engine tune up w/ all new hoses, breathers and upper seals.
  • Powder coated intake manifolds, plenum, upper OEM tie bar, rear exhaust heat shields & bumper grill. (in house).
  • Gauge cluster odometer repair (3d printed gear, in house), w/ calibration, OEM gauge face installation.
  • Custom bumper grill brackets (3d printed, in house).
  • Horn repair wiring, Rear fuse box harness & fuse box repair.
  • Ignition & steering column repair w/ custom key surround (custom designed and 3d printed, in house).
  • Engine and transmission mounts.
  • Rear Brakes pads and rotors.
  • Under hood pad (Genuine OEM).
  • New OEM decals in engine compartment.
  • New OEM VIN decals in driver’s door jamb w/ tire inflation decals.
  • Strip off old “Porsche” & “928S” decals on rear bumper, design, cut and install graphics .
  • General service & maintenance, (Oil service, plugs, cap & rotors, plug wires, fuel filter, etc).
  • New Michelin Pilot Sport Tires.
  • Buff and polish wheels and paint.
  • Buff and polish all windows, inside and out.
  • Rock chip and scratch paint repair.
  • Gear selector repair.
  • Driver’s door check fab and repair
  • High torque starter.
  • Rear Brake pads and rotors
  • Front ball joints.
  • Four wheel alignment and more.
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T4 Eurovan Coolant Bottle Bracket Adapter

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T4.5 Eurovan Coolant Bottle Bracket Adapter

We had to make a custom adapter for a T4.5 Eurovan Coolant Bottle Bracket Adapter the other day. We needed a new coolant reservoir for our customer’s 2001 Volkswagen Eurovan VR6 MV. The warehouse sent me the wrong reservoir (Ver C, and not a Ver E). (701 121 407 E). The Ver C is for 1999-2000 Eurovans with a 12v VR6 engine, however all the connections and hoses are the same. It’s just 180º off from the one we needed. Apparently the Ver E coolant reservoirs are no longer available (NLA) and virtually impossible to find. We searched Classic VW parts, eBay and other sites and came up with zero results. Ver C is still available, however it is also hard to find, but they are available special ordered new from Europe. If you need a Ver C reservoir, we can get one for you.

Instead of wasting time trying to find a new one, or installing a used part, we drafted a file in Fusion 360. Then we 3d printed this bracket. Printed with PA12-CF Polycarbonate Carbon Fiber (25%CF/75%Poly). The bracket is safe up to 220c / 428ºF. This will adapts the older C style bottles with the overflow return on the left / drivers side. These other tanks are readily available. Furthermore, this will fit so the left / drivers side electrical connection (coolant level sensor) fits the configuration for Eurovans with the Ver E bottles. Fits 2001+ T4.5 Eurovan / Transporter / Caravelle – 24v Engines, with the bottle that mounts to the core support. We also installed some brass inserts so we can just bolt it right in and the tank can be replaced it in the future, if need be.

Version 2.0

We revised our design a little to make it both easier to print and use less material. It’s just as strong as Ver 1.0.

 

More Info

For more information on how to get your Volkswagen Eurovan Repaired, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

Purchase

If you would like to purchase one of these. You can do so by clicking the link below. These are made to order, so the turn time on these is approx 3-5 days to ship + shipping time.

Click Here to go to the shop site.

 

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1984 Porsche 928 S Bumper Grill Restoration

This 1984 Porsche 928 S has been in the shop for some repairs, service, and minor restorations. It was a gray market car, imported to the USA and originally sold in Germany.  Some modifications had been performed at different shops previously that was not to our customer’s liking.  One of the items we repaired in house was rebuilding the transmission and repairing the broken gauge cluster. Another item was trying to find a new old stock OEM exhaust to replace the awful sounding aftermarket exhaust – which to our amazement, we did. Another item on our customer’s wish list was to source a original lower center, 928 S bumper grill.

Sourcing the Grill

We were able to source a complete unit, in decent shape, which was not inexpensive even in this poor condition. We looked over the product listing photos and knew a thorough restoration was going to be necessary. This was definitely something we knew we could tackle in house. These photos below show the condition when the grill arrived.

When we received the grill we noticed all the hardware was rusty, so that would need to be refurbished or replaced. Also, the plastic brackets that hold the aluminum grill inserts were painted. They were also on the brink of breaking and extremely flexible. Those would also need to be replaced. Even though the brackets are still somewhat available on some specialty websites, we had an idea on how to upgrade these while still retaining the OEM look. Since we have multiple 3d printers in house, this technology was first thing that came to mind.

Disassembly

First, we started by disassembling everything and bagging and inventorying all the hardware. We took the metal grill inserts to our in house powder coating department to get stripped, blasted and coated.

Drafting the CAD Files

While the grill inserts were in powder, we took the brackets and scanned the profile them on a flatbed scanner. Since flatbed scanners, scan to a 1:1 ratio, we knew the profile sizing and dimensions on screen would be 100% perfect. We took the scans into Adobe photoshop and manipulated the contrast to make it easier to see the profile. After that, we saved the file and imported it into Adobe Illustrator. This is where we created vector outlines of the center and outside brackets. After the profiles were established, we deleted the imported scanned image and exported the file to a CAD format. We imported that into Fusion 360, where we drew up our 3d model for printing.

While in Fusion 360, we added additional supports, removed all the recesses that the OEM bracket have and pocketed each of the 5mm screw holes. Below is the transition of the files, from start to finish.

Flatbed Scans
Illustrator Vector Profiles
CAD Drawings Bottom
CAD Drawings Top

After the Fusion 360 CAD drawings were complete, we exported these to a .STL file and sent them to the 3d Printer. Our AnyCubic Kobra Max is capable of printing 15.9″ x 15.9″ x 17.7″ Tall. We can print a wide variety of materials such as PLA, TPU, and for more industrial applications, carbon fiber nylon blend.

Once the parts came off the printer, we mocked up the grill inserts to the brackets. To our amazement, the brackets fit really well, directly off the printer. Immediately we noticed how much stronger these were compared to the OEM brackets. Furthermore, the reinforcements allowed for very little flex to the upper grill section. We performed some minor finish work and deburred the pieces. When the grill sections came out of powder coating, they would be ready to assemble.

Assembly

At this point in the project, the grill inserts were out of powder coating and ready to go with a fresh coat of Cardinal Powder Semi-Gloss Black T002-BK08. We now started assembling the grill. However, one thing that was not compensated for while designing the brackets was the thicker tolerances.  When we reinforced the brackets joints in programming, we made them thicker than the OEM measurements. Our hardware was a little too short. We sourced some metric black oxide socket head screws that were 3mm longer.

While installing the bumper grill, we found out a interesting thing. The North America (NA) bumpers grill brackets are different than the European E-Code bumpers. The brackets have a slightly different mounting location due to the fact that they are slightly shorter. To sold this, we had to modify the lower mount to be able to accept the NA brackets. It wasn’t worth printing new parts as we just had to drill a hole in each lower bracket and trim off the bottom tab just a little.

This is how it looked after installing the grill:

In conclusion, the assembly went perfect after sourcing those. Overall the project turned out really nice.  We believe our customer will be really happy with the final outcome. Stay tuned for our next post where we remove and install the rear Porsche 928S decals and repair the gauge cluster using 3d printing technology again.

For more information on how to get your Porsche back to OEM condition, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

 

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Project 1991 Mercedes-Benz 560sec

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Project 1991 Mercedes-Benz 560sec

It’s been a long road to completion but we finally got Project 1991 Mercedes-Benz 560sec finished today. Our customer came in about 6 months ago wanting to do a air suspension install on his 1991 Mercedes-Benz 560sec. We wrote him a quote based off his needs and some suggestions from Meister Werks. After approving the quote we ordered all the parts necessary to install his custom setup. The customer also wanted us to have the bumpers, side mouldings, mirrors and door handles painted white to match the body. We contacted our friends at Automotive Solutions to come out and do all the body work, prep and paint.

Fast forward a few weeks later, Covid-19 / Coronavirus hit the Seattle area and thus started the parts delays. It took a few months of waiting to get all the parts in. A few months later in March, we finally received everything and the install started very soon after.

Install Begins

We began the install by removing the bumpers, side mouldings, mirrors and door handles. While these parts were out, we started polishing the OEM stainless steel trim. After all the parts went into paint, we began the air suspension portion. We started the air system by disassembling the custom stereo setup in the trunk. The car stereo installer had fabricated a custom enclosure to house the rose gold plated air tank, Air Zenith air compressors and Airlift 3p manifold. We bent custom hard lines, powder coated them white (to match the body) and affixed all the fittings to the components. After we did this, we install them into the custom build enclosure. After that, we wired the Air Zenith OB2 compressors with 4 gauge wires and 80 amp fuses. We also ran the harness to the Airlift 3p manifold, connected the remote wire to the ignition on circuit and installed the 3p controller in the Mercedes-Benz 560sec center console. 

We had many issues with the custom air bags we purchased from a company in Germany. The bags were rubbing on the body and the upper bag mount did not line up with the control arms. Countless hours corresponding, assembly, disassembly, reassembly, photos and diagrams were sent to the manufacturers. After weeks of communications, we

finally got results and newly machined parts were shipped from Germany. After 3 additional weeks, we received new parts. Unfortunately the parts still did not work right. So we decided to machine the new parts in house to get them to work. What we machined was perfection and will be able to replicate this on any future projects. The Mercedes-Benz is now able to air up properly, lay frame and not rub on the body. These additional modifications to the air suspension was much better than the original kit.

More Custom

We also had to delete the Mercedes-Benz factory hydraulic suspension. To do this we removed the rear shocks, removed the hydraulic pump on the engine and machined a custom block off plate. We used 6061 T6 aluminum to machine this part in our inhouse machine shop. We also made a custom gasket on our CNC cutter. Everything installed perfect, with no leaks or issues.

The components now installed, we attach the air lines using OEM brake line clips to secure the air lines in place. While all the the work was being done, we assembled and sealed the custom rose gold plated AMG wheels and mounted and balanced the tires. After test fitting the wheels, we knew we needed spacers on the front to give this beautiful Mercedes-Benz 560sec a flush fit when rolling down the road.

After all this hard work, we finally were able to test the system for air leaks, button up the trunk and make sure all the small details were handled.

Project 1991 Mercedes-Benz 560sec Build List

  • Airlift Performance 3p management
  • OB2 dual air compressors
  • 4 Gallon Specialty Suspension seamless air tank – plated rose gold*
  • Custom hard lines at Meister Werks
  • Air suspension install at Meister Werks
  • Front bags & hydraulic pump block off plate custom machined at Meister Werks
  •  Rose gold plated* AMG wheels & OZ lips & barrels assembled and sealed at Meister Werks
  • Bumpers, mirrors, door handles, moldings, body work & paint at Meister Werks by Automotive Solutions
    * All custom rose gold plating done at the customer’s shop in California.

To make an appointment for your custom air ride, stop by or call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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Vintage Car Week at Meister Werks

This week is vintage car week at Meister Werks. We’ve had a number of vintage vehicles come in such as a ’64 Coupe Deville, ’64 – 13 Window VW Bus, ’71 Beetle and a 1977 Datsun 280z.

Coupe Deville is in for a air compressor refresh and wiring. 13 Window Bus came in for a plethora of service, repairs and upgrades. The Clementine Orange Beetle was dropped off for a crate engine install, all new upholstery, disk brake conversions, powder coating and many more custom items. Lastly, the ’77 280z came in for some repairs and some custom powder coating.

The Z and the Coupe Deville will be done next week, although the VW’s will be ongoing projects over the next month. Stay tuned for further progress reports on each vehicle.

 

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Powder Coated Brembo Calipers

Powder Coated Brembo Calipers

Last week, we Powder Coated Brembo Calipers for a customer. The customer purchased brand new calipers for his 2015 Lexus GS350. Since these were brand new in the box, there was little prep we had to do. We outgassed the machining oils by baking the calipers for a short time in our powder coating oven. After the calipers cooled off, we prepped them with solvent, masked off the critical areas and plugged all the threaded holes. To mask and plug the holes, we use a high temp silicone tape and plug that will withstand the temperature of our oven. The makes for an easy and trouble free installation for our customers.

After the prep is done, we powder coat the calipers, 2 coats of super durable wet red and 2 coats of clear coat. This will ensure the maximum amount of protection against road debris, discoloration and durability. As you can see, the finish turned out flawlessly.

Questions We Have Asked

Many people ask, “Why don’t you seperate the calipers (if they are 2 piece) or remove the pistons? The answer is many reasons:

  • First, you don’t want to separate the calipers. We’ve encountered customers who tried this and they will never seal again. This is because the caliper may slightly become disfigured from relieving stress and the torque to reassemble them. Also, the heat when baking does not help in this scenario.
  • Second, the pistons will heat up at the same rate of the caliper housing. This will protect against any media or powder getting into the brake cylinders. On used calipers, we have to media blast the brake dust off the calipers. We do not want to get meida inside the cylinder, which could affect braking performance.
  • Third, the dust seals. This will not affected by temperature change. Furthermore, the seals stay perfectly sealed and are make to take the temperature of high performance braking temperatures.
  • Lastly, Powder Coated Brembo Calipers is much easier for us as there is less to mask and prep.

Used Calipers

Before & After

We can coat used brake calipers, however the process requires more prep. We have to heavily outgas the caliper to get all the brake fluid out of the caliper. The powder coat will be destroyed if any brake fluid gets on it during the curing process. We also have to remove `100% of the old brake dust. Brake dust is non conductive and the powder will not stick to it. If the calipers are on the vehicle, we charge more to remove, prep, coat and reinstall them. They also need bleed so essentially, if they are already on the car, it’s sometimes better to paint them. You can see this process by clicking here.

For more information on how to get your brake calipers painted or powdercoated, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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500+ HP Audi TTRS

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TTRS Performance Upgrades

The inline 5 may be the most stout engine ever produced by Audi. But for some, the best is simply not enough… A long time customer brought in his 2018 Audi TTRS for a Carbon Cold Air Intake, 4 inch Turbo Inlet, Wastegate Lines and to top it off with a Stage 1 tune all supplied by Unitronic.

 

UNITRONIC STAGE 1 FOR AUDI TTRS MK3 2.5TFSI EVO
• STOCK POWER: 400HP / 354LB-FT
• After Tune: 476HP / 469LB-FT

Unitronic Stage 1 Performance Software is for vehicles with 91 octane / 95 RON fuel, on a completely stock car. It is the performance upgrade that will result in the most gains! Performance Software for your ECU Box Code is subject to availability. 2019+ models may require to have the hood opened during the flashing process.

UNITRONIC STAGE 2 DSG FOR AUDI TTRS MK3 2.5TFSI EVO

Flashed directly through the (OBDII) Diagnostic port of your vehicle (10-15 minutes). Unitronic’s TCU Performance Software calibration enhances the gear shift speeds making them up to 70% quicker. D-mode (Drive) is for everyday daily driving and economy, while S-mode (Sport) is for faster acceleration. Unitronic’s TCU Performance Software unlocks the factory launch control limiter. The OEM launch control limiter blocks the engagement of launch control after only 200 launches.

Unitronic’s Stage 2 TCU Performance Software calibrations increase TCU torque limiters to allow for an increased output. It’s been developed alongside Unitronic’s upcoming Stage 2 ECU Performance Software for the ultimate overall experience. Unitronic’s Stage 2 TCU Performance Software calibrations increase clutch clamping pressure. It is perfect, alongside Unitronic’s Stage 2 ECU Performance Software. This supports an increase in engine torque output and ensuring that the clutches properly grip . This also will help for the higher output to be sustained. Includes all Stage 2 tune variants and all lower software stages as well.

For more info on these products, check out the Unitronic Website by clicking here.

To make an appointment for your TTRS, Audi or European car, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

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Powder Coated Production Run of Reinforced Clutch Forks

Powder Coated Production Run of Reinforced Clutch Forks

Today we powder coated a production run of reinforced clutch forks for Flipside Customs. These VW clutch forks are for 02A & 02J transmission and reinforced with the factory clutch fork in house at Flipside Customs in Renton, WA. These new OEM forks receive a TIG welded finish with water cut gussets. Factory forks are know to bend and go bad. Symptoms include increasing difficulty getting into gear, especially 1st gear. Really fast clicking or chattering sound in neutral with clutch completely let out. Sound may completely disappear if you press in the clutch.

If you are interested in getting powder coating quote for your production run of in house manufactured parts, contact us at 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

About Flipside Customs

Flipside Customs owner, Rob Hancock, specializes in custom design, fabrication and welding services.  Customers can expect an increase in functionality, performance and overall quality with his 20 years of experience.  Rob started his career working on street rods; a passion passed down through the generations.  While continuing to work on street rods, he branched out to production based welding on speed related products. He also gained experience in the machining industry which yet again expanded Flipside’s diversity.  Rob has continued to use his skill set to benefit his customers in ways that separate his work from others.

Also, questions like; “Is this possible?” will be quickly answered with “let me show you how!”. As an avid racer himself, he saw and experienced several areas to improve on during his time on the track.  He began designing, modifying and fabricating custom race components that have increased both performance and functionality both on and off the track. As a lover of both two and four-wheel vehicles, Rob has expanded the business to include custom motorcycles, street, and race cars as well as off-road vehicles.  If you are interested in what Flipside Customs has to offer, please contact Rob at Rob@flipsidecustoms.com.

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