Twin Charged FD - Fraternal Twins

[RX SE7EN]

Hey Everyone,

The purpose of the build is to twin charge my FD. Yes, I said twin charge. I’ve been researching for about a year now, this type of thing isn’t very well documented anywhere (well from what I’ve seen anyways). So I’ve been slowly designing the system and collecting parts. My goal is to have it working by deals gap, not sure if it’ll be done, but that’s the goal. Before I get started, I’ll just say that I know that these kinds of threads come along and then nothing ever happens, and that could very well end up being the case here, but I’m going to give it a shot and see what happens. I welcome all constructive ideas, but please refrain from posting negative criticism (I’ve made up my mind to try this, no turning back now)

I’ve currently got the Greddy T78 kit. When I had it tuned, it made 454whp at 18psi. Which is a little low, and the previous owner blew an engine on the car so I think it has seen better days. I’ll be sending it off for a rebuild in sometime this month, so even if this project doesn't work, I'll at least gain a fresh turbo.

I bought a remanufactured Eaton M62 supercharger in September. It’s got a clutched pulley and I plan to have it disengage after its done doing its work down low (1k – 6k rpm), then the turbo will take over entirely. I’m aiming for around 500whp somewhere around 20psi (with meth injection). But with torque down low, and no lag. If this actually works, I’ll upgrade to a larger turbo to make more top end power with no lag.

I’ve been debating going 20b, and would if the car wasn’t already single turbo and using the TEC GT ecu. Going 20b would require changing out the ecu, buying a 20b, buying a mounting kit, and paying someone to make new piping for me. Those are the big costs that I would incur; I know there are many other small items that would add to it. So the next best thing is attempting to grow my hp level, but decrease lag and increase torque down low. That’s where the twin charged setup comes in. And if it works, I can then transfer it to a 20b application a few years from now, which would be the ultimate setup.

I've come across a bunch of videos on youtube during my research:
Coolest silvia I’ve ever seen:
http://www.youtube.com/watch?v=4SjNgVH_HN0

And my true inspiration: go to 1:60, it’s instant boost (I know there is no load on the engine, but still cool)
http://www.youtube.com/watch?v=wLB2P1ziXYA


I’ve found numerous threads on twin charging, on many different forums, but never really anything that shows start to finish, with a DIY. And definitely nothing on this forum. A lot of the info I found was geared more towards big V8's with short rpm ranges with a supercharger on top of the engine and turbochargers compounding through the supercharger, with both systems on all the time, so those don't really help me that much (wouldn't be great on the FD). But I was able to find a picture of what could possibly be the best FD setup ever: (couldn’t find pictures at completion or information on how it was controlled)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/P6210722.jpg

[RX SE7EN]

Also, TitaniumTT has been absolutely essential to the build so far. Thanks Man!!!

He's been doing all of the welding (which you'll see pics of later on) and also letting me use his tools to make the pieces I need. And he's also a great source of knowledge, having someone to bounce ideas off of is great.


Here is a quick recap of where the project is and where it needs to go.

My current setup:
94 R2 FD
Brilliant Black
Street ported engine with oil and coolant passage mods
HKS Hypermax coilovers (courtesy of RX7 Boutique / PureRX7)
Racing Beat Sway bar (front)
PFS Large Race SMIC w/ duct
Meth injection (2 x 625 ml/min nozzles w/braided lines to shurflo pump, Snow Performance progressive controller)
TEC GT ems with upgraded coils (coils located by brake vacuum booster & master cylinder)
Battery relocated to passenger bin
Greddy T78 turbo kit
Greddy Elbow
3” exhaust from turbo back (Borla resonator, HKS catback)
1680 secondary injectors
720 primary injectors
SARD FPR
Aeromotive Tsunami fuel pump (in tank)
HKS SSQV BOV
HKS EVC IV boost controller
Short Shifter (came with car, not sure of brand)
PLX DM100 gauges x2 – modules for boost, wideband AFR, oil pressure, fuel pressure, water temp, oil temp, AIT
Taylor 8mm spark plug wires (made them myself, actually turned out really nice)
Eliminated AST
Koyo Radiator w/ stock fans

New setup requires the following changes:
Power Steering delete – the supercharger is going to be placed where the power steering pump used to be, so I found a good used Maval manual rack (thanks Allrotor)
Oil Filler neck – this needs to be modified and routed to the rear of the UIM, as the rear of the supercharger takes up all the room in the neck’s stock location.
Most likely a rebuild too

[RX SE7EN]

Stock power steering and A/C bracket:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0345.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0344.jpg

Cut, Cleaned, and Squared:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0338.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0337.jpg

Aluminum mounting plate, there are two of these, this one is fixed to the bracket. The other is larger and is what the supercharger will bolt to. This bracket is only tacked together, now that I know it fits, we're going to weld it up and also add some gussets to strengthen it.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0348.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0346.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0347.jpg

Test fit:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0339.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0340.jpg

The larger plate (for bolting the supercharger down):
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0341.jpg

Supercharger: close to its final place, I need to trim part of the throttle mechanism bracket on the throttle body, but things are lining up nicely:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0342.jpg
Not much room but it looks like it'll work!

[RX SE7EN]

Here is the modified bracket, it now has 4 gussets to make it strong:
Check out these welds, I owe a HUUUUUGGGEEEE thanks to TitaniumTT, although he mostly lives on the "other" forum. I need to duplicate this over there.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/photo2.jpg

I cleaned and cleaned, and baked and baked, but I think because this piece sits under the power steering pump, and I've had leaks before, the cast aluminum just soaks up so much oil and grime, making it a little tougher to weld, but it came out really nice regardless.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/photo.jpg

And I got a big package, with 6 little packages inside
Piping!!!!! - 2.75" diameter, 2x18" straight pieces, 2x45 degree bends, 2x90 degree bends:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/pipes1.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/pipes2.jpg

I've also modified my throttle body throttle linkage to give me a little more room. I took off the cruise control linkage, and moved the normal throttle linkage into its spot. The little bushing that holds everything in place came apart really nicely (it's just pressed together). Then I swapped the outer throttle cable holder to the inside where the cruise control cable linkage was. Now I just need to cut off about an inch from the small bar that the spring butts up against, this will give me room to slide the supercharger back just a hair.

Throttle Body (you'll notice it's there is only one piece to hold a thottle cable, which now sits where the cruise control cable hookup used to be):
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/throttlebodymodified.jpg

Close up & removed cruise control cable hookup:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/cruisecontrolbracketremoved.jpg

Piece I need to cut about 1" off of, which will give me just enough room for the inlet to the supercharger. This is what the spring that springs back the thottle valves loads against.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/throttletocut.jpg

sorry for the poor Iphone pics

[RX SE7EN]

Check this out!!!

Finally got the baseplate welded to the bracket. Absolutely amazing looking (well I think so anyways).

Again, a huge thanks to TitaniumTT for the great welds.

Now all I've got to do is mount it, line up the pulleys, and then drill 4 holes in the plate for the supercharger to secure the supercharger through its stock mounting holes.

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1819.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1818.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1817.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1816.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1815.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1820.jpg

After its bolted down and secure we can start fabbing up the piping

[TitaniumTT]

Sweet! Finally you made it over, awesome! Glad to help people that appreciate it, ya know? So yeah, welcome to RCC, you won't have any negative critismn over here, we don't roll that way.... but check out post number #4 though... copy/paste got ya :rofl: I don't mostly live on the other forum, they perma banned me again because I am of no value to the community apparently :smilielol5:

You said send it out for a rebuild... I thought you were talking about the engine at first! Got me worried you found something out before we did the obligatory comp test.... which as someone pointed out to me last weekend is just like an AIDS test, you want to know, but do you really wanna know? :lol:

[RotorDad]

I saw this on the other forum & I'm glad you decided to share the build over here. I remember I had mentioned the idea of twin charging over there & all I received were negative comments. Very interested in seeing how the build progresses goes for you.

[djmtsu]

Looks like good stuff! Brian, help him get this to DGRR, as long as it doesn't make your FC suffer!

I am fond of all the liquor in the background of nearly every pic. Win.

[vex]

wait... I'm confused... Are you compound charging it using a twin system, or are you going to be doing some crazy valve work and using the turbo's separately from the super?

(In other words are you going to be running the super charger pressure into the turbo's or the turbo's pressure into the super, or are you going to be running them at the same time and which ever one is running the higher pressure you'll be using)

[RX SE7EN]

The flow will be:
Clean Air -> Turbo -> Supercharger -> Throttle Body -> UIM

I was originally going to have some valving, allowing the turbo to bypass the supercharger at high RPM, but have since decided to keep them in series (compounding) all of the time. Once I have it working, then I'll do some R&D to see if I can come up with a bypass system. I've got a good design for it, but time constraints and cost will keep me from exploring it for a little while.

Your confusion may have been caused because I copy/pasted my old build thread from the other forum, and skipped a lot of the discussion around which routing combination to use. My research concludes that compounding the turbo into the supercharger is absolutely better than vice-versa. I do like the idea of a bypass system (would really come in handy if I decide to use a smaller than stock supercharger pulley, so i can almost over-rev the supercharger by 6k rpm engine speed for even more boost down low and then let the turbo take over). But that can wait until I have a basic system that works.

And I swear I'm not an alcoholic. My kitchen table triples as a liquor cabinet and car part picture taking stand haha.

[My5ABaby]

I'm really interested to see where this goes. I'm pretty sure if it's finished for DGRR I've got dibs on a ride. Maybe the same deal I've got with B...

[vex]

So how are you going to cool down the compound charge? It would seem to me that the increased pressure would cause a slightly warmer intake temperature (PV=RT and all).

[RX SE7EN]

A few different ways:
1. the wastegate on the turbo will be opening earlier due to the compounding multiplier effect that the supercharger will have on the turbocharged air. Meaning the turbo will actually have to do less work in order for the engine to see any desired PSI. And since the supercharger alone will never produce more than 10-15psi (due to pulley sizes), the turbo wastegate will regulate all boost above those levels by reducing turbo CFM (allowing more exhaust air to bypass the turbine).

2. Intercooler. My above post is flawed, sorry about that. the true flow is this:
Fresh Air -> Turbo -> Supercharger -> Intercooler -> Pipe to throttle body (methanol added) -> throttle body -> UIM.

3. The methanol mentioned above will also reduce heat :)

[prrex4ever]

Looking forward to seeing the final results, looking good.

[vex]

Don't let Peter see that... :rofl:

[muibubbles]

lol @ brian and the aids comment.... hahaa

yeo i was about to send u a link to this thread... tricked me with the alter ego name switch!!

[RX SE7EN]

yeo i was about to send u a link to this thread... tricked me with the alter ego name switch!!

Haha yeah, I figured I'd switch my name to what it really should be. My other screen name (Chudson coupe for those that don't know) was created for my G35 coupe when I lived in the Hudson valley region. And since I was on those forums with that name, I kept it simple and just kept it when i joined the other rx7 forum.

The only reason i haven't been on here that much is because I'm usually just browsing 3rd gen classifieds, and that section on here doesn't have too much volume yet.

RX SE7EN is actually the license plate that I was going to get...until NY changed to the stupid yellow plates just when I was going to order it :( I don't want to switch over to that awful/ugly yellow plate, so i'm sticking with the old style plates.


Bubbles, any chance you'd like to media blast some parts for me? I'd like to clean them up before sending them out for coating. I could trade you some parts for the labor?

[RX SE7EN]

Check it out, bolted down and lined up (the bolts are temporary, I'll be ordering some better fitting, nicer looking bolts and spacers this week):
(Stock Belt works, but still working on mounting a tensioner)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1828.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1829.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1830.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1831.jpg

This is the stock outlet pipe from the mercedes. I bought this so that I could have the smoothest transition coming out of the charger as possible. I'll be hacking it up and putting on a 2.75" pipe pretty close to the supercharger, so the big hole that you see won't be there for long. Notice it fits under the strut bar :)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1832.jpg

Relocated fuse box to make room for intake piping into the throttle body from the intercooler:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1833.jpg
The big box is mounted on its original bracket which I cut and bent to fit in the new spot, and bolted to a factory threaded hole. I still need to make a bracket for the smaller box.

Now its onto the piping.

I also removed the T78 turbo today (it started smoking at the end of last summer). I got the cold side housing off, the blades look great. I didn't get the hotside off yet, i'm a little worried about the blades though, before I got the car the engine had blown. and when I was getting it tuned last time they said it wasn't making the power that it should.

I got the band off that holds the hot side housing on, there was oil underneath it, so I at least I found the source of the smoldering smoke coming out from under the hood after it got hot.

There is a little slop in the shaft, I've seen worse, so hopefully the rebuild doesn't cost too much.

Does anyone know a good turbo rebuild shop? Must be someone that can do the T78.

[RX SE7EN]

What are you guys using for circuit breakers when relocating your battery to inside the car? My battery is in the rear bin and doesn't have a breaker.

[TitaniumTT]

Waytekwire.com or Delcity.net have marine grade buss breakers for 1/2 the $$$ that WestMarine will charge. I run a 150A

How's the piping coming along man?

[C. Ludwig]

^ yep

http://www.delcity.net/store/Hi-Amp-Surface-Mount-!-Manual-Reset-(Switchable)/p_193073.a_1

[TitaniumTT]

^yep, or for those of us with what would seem like way too much time on our hands.... surface mount
http://order.waytekwire.com/products2/M50/140/200/500/1/Marine%20Rated%20Panel%20Mount/Circuit%20Breaker%20High%20Amp/Circuit%20Protection/

[RX SE7EN]

So I've hit a slight roadbump. I sent my Greddy T78 turbo out for a rebuild as it started smoking last fall. Prior to that, it had never made great power and was laggy (my car came with the kit and a blown engine), I had put a new motor in and never rebuilt the turbo or even took it apart. I sent it off for a rebuild and this is what is wrong with it:

Bad seals, I knew that, because oil was leaking.
Useless turbine wheel, I was hoping this wouldnt be the case.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_20110329_183009.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_20110329_183140.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/Turbine_blades_2_2.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/Turbo_blades_5.jpg

The cost for a rebuild quickly escallated, couldn't even find a turbine wheel/shaft in the country. There was one in Japan the rebuild shop could get for $415 (the turbo is no longer in production), they showed me the quote straight from the supplier and were going to give it to me at cost. So that put the rebuild cost to around $900. Way too much. The shop was Midwest Turbo Connection. Even though I can't vouche for their work, their customer service was excellent, and got back to me extremely quick with multiple updates while they were trying to track down the wheel, and also sent tons of pics for me. Customer service like that is hard to find.

So I've been shopping around, and the only thing I could find that's roughly the same size and decently price is a BW S366. So I'm going to try to pick one up next week. I couldn't even find anything used for decent price :(

[RX SE7EN]

It's official, I'm now a Borg Warner S366 owner.
Here is the link: http://www.diesel-plus.com/dd_turbo.cfm?npid=9784
http://www.diesel-plus.com/images/borgwarnerairwerks-S300S.jpg

Basically, it's a little larger than my old T78, and will perform better. This is actually on back order and will be hard to get until May, but Mike at Southeast Power Systems (Diesel-Plus online) was able to get me hooked up and its on its way. Great customer service, and great prices. Every place else I tried just said it was on back order from BW and they wouldn't be able to get it until May. But Southeast Power Systems figured out how to get one to me quickly.

It's a 66.1mm compressor, with a T4 twin scroll housing, .91 A/R. I would have liked a little bit bigger A/R, but its not really available yet from BW. I've heard the 1.0 and 1.10 will be coming out in a few months. If I need to, I'll upgrade later on.

The T4 inlet configuration looks slightly different than my T78, so I'm not sure if I'll have to modify the exhaust manifold at all. I'm hoping the new housing doesn't touch the LIM.

[My5ABaby]

Gotta love buying a turbo for a 6.0L engine to go on a 2.0L engine becuase the 2.0L engine rocks the 6.0L engine's world.

[RX SE7EN]

Haha, yes it is a large turbo. It's not too much bigger than the T78 though, pretty comparable to the T88. I was actually pretty happy with my T78 the way it was, and as you can see, the turbine wheel was in bad shape. So even if the supercharger doesn't work, this should still be an improvement in response.

[tweiss3]

very very nice. I can't wait to see it all together

[TitaniumTT]

Gotta love buying a turbo for a 6.0L engine to go on a 2.0L engine becuase the 2.0L engine rocks the 6.0L engine's world.

2.0L???? Whatchutalkingbout???? This is a 2 rotor!

Speaking of... when we doing some more welding Colin? Did you manage to get everything fit as far as piping goes? SC officially mounted? I noticed my little gift for you is still sitting in the box in my box :suspect: I'm officially back in the garage tonight working. I won't be able to take tomorrow off, hoping for Friday but doubtful. Next week is going to SUCK, I know that. Brakes are in AZ being finished, turbo's are in AL being finished, driveshaft is in stamford and needs to be picked up, remeasured, probably built again, powdercoating in Stratford, seat in Norwalk, head up my ass, and time is ticking away.... :willy_nilly:

[RX SE7EN]

I've barely gotten anything done :(, I do have the supercharger mounted, and my oil lines came in. So thats a plus. I cut the inlet and outlet pipes, but haven't cut the new piping that needs to be welded to them.

I did get the bumper off though, (my garage got rammed by the neighbors car and a tool box flew into my bumper :(, also cracked my r-magic fender)

So that needs to get fixed too. A whole lotta suck going on haha. I'll have to turn it up this weekend.

[RX SE7EN]

Huge updates coming, pulled an all nighter saturday, and got almost all of the piping done. The only piping left is the easy stuff (almost only straight pieces to go, and no more welding piping to cast aluminum)

Turbo also came in, it fits on the manifold just fine. Even more clearance than before. I just need to cut the 4bolt flange off the downpipe and weld on the V-band flange.

I'll also be coating the turbine housing with DEI high temp coating.

My belts came in today, we have tension :) and I installed my Tweakit racing idler pulley for the water pump belt (I purchased it last year haha).

Pictures will come tonight.

[RX SE7EN]

My belts came in today, I bought 40", 40.5" and 41" gatorback belts to see what would fit best. 41" fits on great and has tension. I'll be using some extra nuts to raise the supercharger up about 1/4" to put the final bit of tension on. Unfortunately I ordered 5 rib belts by mistake, I need to order a 6 rib instead. At least I've got the tension right though.

I'm also ordering a 5 rib 35.5" belt for the water pump, alternator, and TeakIt idler/airpump delete belt. I'm glad I finally installed that.

Here is the first round of pics from last weekend (please keep in mind these are prior to grinding down/touching up welds. I'll spend the time making them pretty once I know it actually works):

First up, inlet for supercharger. I actually purchased the stock mercedes cast piece and planned to weld my own pipe to it, but due to clearance issues under the UIM, we just made the entire piece from stock.

Flange, will have pipe welded to this side
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/037-SCinlet1.jpg

mates against supercharger, need to grind these down to get a perfectly flat flange.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/038-SCinlet2.jpg

With pipe attached: This pipe will run under the UIM, and curve up next to the secondary fuel rail where many have their aftermarket fuel pressure regulator located, and then into the outlet of the supercharger.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/039-SCinlet3.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/040-SCinlet4.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/041-SCinlet5.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/042-SCinlet6.jpg

need to plane this flat:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/043-SCinlet7.jpg

[RX SE7EN]

Supercharger outlet pipe:
Will be routed from supercharger across the front of the alternator, over the thermostat housing, and into the intercooler:

What i started with:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_1832.jpg

What I've got now (same angle)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/045-SCoutlet2.jpg

(opposite angle)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/044-SCoutlet1.jpg

This would interfere with the thermostat housing, so I had to modify the Tstat housing in order to provide for a smooth transition into the intercooler. Please keep in mind that my AST has been deleted for a long time.

two pieces that used to be one: Tstat housing:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/034-Tstathousing3.jpg

In process:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/033-Tstathousing2.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/032-Tstathousing1.jpg

Done and tons of clearance for my new supercharger to intercooler piping:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/036-Tstathousing5.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/035-Tstathousing4.jpg

I use the 2nd gen metal fill neck (cut the flange off and welded to the new piece), the 3rd gen fill neck is plastic

[RX SE7EN]

Greddy Elbow:
The extreme angle on the normal greddy elbow wouldn't allow the inlet pipe to clear the supercharger, so I had to change the angle. Now the pipe will run closer to the strut tower where the fuse box was.

Original:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/046-elbow1.jpg

Cutting:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/047-elbow2.jpg

Tacked together for mock up:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/048-elbow3.jpg

Final (angle wasn't quite enough to provide clearance in the above pic, so this is the final piece which was cut one more time)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/049-elbow4.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/049-elbow5.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/050-elbow6.jpg

Inside:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/051-elbow7.jpg

Still have smooth flow:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/052-elbow8.jpg

There are three tapped holes, 2 for meth nozzles, 1 for intake temp sensor. I really think all of these pieces came out great.

Please remember, these still all need to be cleaned up some, but the welding is great. Thanks again Brian!!!

Now we just have to make a few easy pieces. Straight pipe with BOV from intercooler outlet to greddy elbow. and a pipe with a 45 degree bend from the supercharger inlet pipe to the turbo outlet.

[tweiss3]

Very interesting build. Interested to see the next steps too.

[TitaniumTT]

Huge updates coming, pulled an all nighter saturday, and got almost all of the piping done.

:suspect: Someones a bad influence :rofl:

Please remember, these still all need to be cleaned up some, but the welding is great. Thanks again Brian!!!

Now we just have to make a few easy pieces. Straight pipe with BOV from intercooler outlet to greddy elbow. and a pipe with a 45 degree bend from the supercharger inlet pipe to the turbo outlet.

No worries my friend! All be burning through Saturday night again me thinks so if ya wanna swing by weld up the last few pieces, come on by. Look's like you'll be starting up before I do.

So DJ, looks like she'll be @ DGRRXI afterall!

[TitaniumTT]

Just read it again.... Tension!!! SWEET!!! So tension bolted down, then even more with the 4 nuts underneath moving it up ever so slightly?

When are we doing the obligatory AIDS ereerrrrrr comp test and firing her up?

[RX SE7EN]

hopefully sunday. I have to do my taxes in the morning haha, then work, then car time.

We've still got to adjust the downpipe too, but it looks like it should be easy.

Fingers crossed for the aids test haha, but im a little owrried

[TitaniumTT]

Cooooooooool.... w/e is supposed to be lousy for weather though.... good thing you've got that lean-to ;) Yeah man, whenever you've got that DP ready, shoot me a txt and we'll get it all welded up, and whenever you've got the time, I've got the tester.

[RX SE7EN]

Update: cut the 4 bolt downpipe flange off the downpipe, welded a small piece of pipe, and then welded on the vband flange. For anyone with the T78 kit wanting to do this, you have to cut back the downpipe to just before where it finishes its final bend, otherwise the downpipe is about 1/4" to high to go straight into the turbo outlet.

Check out the fitment now :)

Cut and tacked together, vband and hose clamps holding everything in place:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/photo5.jpg

Half way there:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/photo6.jpg

Complete (there will be no leaks on this vband:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/photo7.jpg

Now I just have to rewrap the downpipe and coat it and the turbo with DEI high temp coating.

I had no idea that the normal heat wrap just disintegrates after its been run for a while. It was literally turning to dust during removal.

[TitaniumTT]

I said DAMYUM that shop is filthy... clean that shit up!!!!! oh wait :rofl:

Seeing as how my car won't be attending.... we're gonna bust ass and make sure DJ is satisfied and this bad ride is @ DGRRXI :icon_tup:

[RX SE7EN]

Worked all weekend again, Deals Gap is coming way to quickly. Still don't know if it'll even work.

I'll let the pics do the talking:

In with the new, out with the old
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0400.jpg

Resprayed manifold (also re-wrapped and sprayed the downpipe):
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0398.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0399.jpg

New turbo oil feed, this sits under the supercharger bracket, and the old hardline was touching the bottom of the mounting plate. So now it's braided -4 AN (black nylon) and won't rub on anything:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0404.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0405.jpg

Since the back of the supercharger partly under the TB, I had to make a new oil fill neck. This will have a -10 AN bung welded to it and a short black nylon braided line will be routed to the rear of the UIM and will be the oil fill point:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0401.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0402.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0403.jpg

Unfortunately, the supercharger air inlet pipe still hits that new oil fill neck, so i had to modify the pipe. I've since modified this 2 more times, and it's going to need a little more persuasion before it will actually bolt down nicely. The oil fill neck and rear of the supercharger are just so close :(
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0406.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0407.jpg

Hopefully I can get this piece fitting correctly. I finished relocating the fuse boxes and tieding up the wiring this weekend. I also finished replacing the old oil hardline (from oil filter pedastal to driver side oil cooler) to -10 AN braided line. The hard pipe would have rubbed on the supercharger bracket. Then I can finish off the final pipes and see if it starts.

Tonight I should be able to put the bumper and lights back on (not fixed though). And I'll also have my new 90mm bi-xenon D2S projectors up and running, finally I'll be able to see at night.

[RX SE7EN]

Just got in from pulling the rear subframe. I had originally started to just replace all of the bushings/pillowballs. I started with the front, then I got bit by the bug and said, "I'm not going to have this apart for a long time, so now's the time to clean & paint". So instead of just new bushings, I cleaned the disgusting wheel wells, resprayed with rubberized coating, cleaned and painted all the suspension arms, installed new rubbers on the ball joints.

And of course, after all that, I couldn't just leave the rear alone. So tonight I removed the subframe, which will now be sent away for powdercoating along with the PPF and driveshaft. I'll paint all the suspension arms, diff, and axles.

I've been painting the suspension arms because aluminum can become brittle unless done exactly right (slow heat, cure powdercoat, and slow cool down). I don't really trust anyone enough to take the risk on brittle suspension arms, so paint will have to do.

Here's a few pics (the theme is black and blue on the entire car):

The subframe is a bear to get out by yourself haha.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0480.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0482.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0483.jpg

A glimpse of the amount of dirt caked onto the front wheel wells:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0436.jpg

The amount that came off just one side:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0440.jpg

A clean wheel well (before new rubberized coating)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0438.jpg (I also sprayed the liners)

Dirty Arms:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0441.jpg

Clean arms:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0450.jpg
These all have the old rubber boots, which i left on to keep paint out of the joints, I then installed nice new boots from Malloy Mazda (Ray's the man)

Primered Arms:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0451.jpg

Painted Arms:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/IMG_0452.jpg


Quick update on the twin charged part of the project, haven't really made any progress on the boost system lately, working on finishing the suspension & undercarriage, then driving it over to my awesome welder's to do some work. While its there, I'll be changing the oilpan and installing the oil pan brace. I'll be taking the engine out when I do this so I can have the subframe powdercoated, engine bay painted, and every piece in the engine bay powdercoated.

I'm doing this at my Brian's place so that we can clean up some of the piping that you can't really inspect when the engine is in the car, so we'll have the engine out, with all the piping installed, and make sure nothing is rubbing and do some other cleanup.

[Force13b]

Very nice. I thought about painting mine but in the end opted just for a nice shinny aluminum finish and called it good. I'll have to go back and do the rubber spray.

[RX SE7EN]

Update:

Rear subframe removed: (out for powder coating tomorrow, along with the PPF, undercarriage braces, and muffler shield)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0495.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0496.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0494.jpg

Diff painted:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0503.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0502.jpg

Axles/Knuckles painted:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0506.jpg

Rear bushings & pillow balls pressed out:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0501-1.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0500-1.jpg

Will be cleaned, painted, with Powerflex bushings and AtomicRex pillow balls pressed in this weekend.

[Force13b]

Update:

Will be cleaned, painted, with Powerflex bushings and AtomicRex pillow balls pressed in this weekend.

How are you setting up your shims with the atomicrex pillow balls. With the lip that is on the lower arm i was thinking of putting the shims on the opposite side encase i ever had to press out the shims and pillow ball. Getting the shims out when they are against that rim would be a pain.
http://i23.photobucket.com/albums/b392/force13b/car/IMG_0110.jpg

[RX SE7EN]

I'll be putting all the shims on the side opposite of the lip built into the arm. AtomicRex said it shouldn't make a difference.

[TitaniumTT]

Everytime I see an update Colin, I dread the day I start working on my FD :rofl:

Like I said, I'm finally "off" this weekend, but I'm dragging you and your better half out on the boat one day ;)

[Garfinkles Motor Works]

wow double wow

[RX SE7EN]

Everytime I see an update Colin, I dread the day I start working on my FD :rofl:

Like I said, I'm finally "off" this weekend, but I'm dragging you and your better half out on the boat one day ;)

Haha sweet, went to the powdercoater, wanted at least $450 for the subframe and PPF, not sure I want to swing it. I'm gonna talk to a local shop tomorrow and see if they can do better.

Any chance you know where I can buy an aluminum die grinding bit (a long one like the one you have for steel). To handle aluminum I read that it needs to be fluted so it doesnt clog, and to use dw40 as lube haha. I've got a sweet idea for my intake, and I'll be doing some heavy duty grinding on/in the UIM.

wow double wow
I hope those are good wows? :)

[20b 3rd gen]

great work

[Garfinkles Motor Works]

Very good wow and better double wow . Good skill to you .Looks like no luck is needed.I die grind alum with kerosine or wd40 using any of my bits ,some do clog if the part goes dry .

[RX SE7EN]

Well, everything is now at the powdercoater, he's going to do all of the rear arms. I didn't do it on the front and went with paint because I'd heard bad things about aluminum becoming brittle, and thats not what i want suspension arms to be, but they assured me they can do it the right way.

Should have everything back in 2 weeks (he's on vacation next week). Then we'll see how well the painted arms in the front hold up once i start driving it.

[RX SE7EN]

Brakes are done!

Before:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0508.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0507.jpg

After:
Front:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0516.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0517.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0518.jpg

Rear:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0515.jpg

The blue is special caliper paint and a slightly different shade than the rest of the suspension blue, but I think it's ok if the Calipers stand out a bit.

Also started hacking up the UIM today, will go strait to a 3" pipe with wiggins clamp to connect to the piping that goes to the intercooler.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0519.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0520.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0521.jpg

[TitaniumTT]

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0518.jpg

Nice dude... REALLY nice. Shit, you got a lot more done today than I did. Thanks again for the help :icon_tup:

[RX SE7EN]

Finally got around to cleaning the rear wheel wells, here is the aftermath:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0523.jpg

Soooo much dirt, and yes, those are rocks (they were stuck on the lip behind the rear mudguard).

[RX SE7EN]

I've got a small update, since I'm cleaning the underside of the car, I took off the muffler heat shield, and I'm cleaning that entire area and will eventually coat it with truck bed liner. The rear wheel wells, and area above the subframe will get the same treatment.

While the subframe is off being powdercoated, I decided to refurbish the heat shield:

Before:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0535.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0536.jpg

After Cleaning:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0538.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0537.jpg

After Paint (not sure how the paint will hold up, but it will look cool for at least a little while)
Exterior:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0540.jpg

Interior (reflective haha)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0539.jpg

My front stoptech braided brake lines finally came in. The rear already has braided SS.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0534.jpg

[RX SE7EN]

Finally made some more progress. Finished cleaning under the rear of the car, and sprayed it with the first coat of truck bed liner. One more coat tomorrow and I can bolt the subframe up.

My buddy came by and I lowered his new porsche. Yes, its the twin turbo V8, chipped and making over 500 hp and torque.
(on the mid height setting in this pic)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_1993.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_1990.jpg

He also has a nice camera, so he took some pics of my car.

Front wheel wells, pretty much done:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/_MG_2032.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/_MG_2034.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/_MG_2030.jpg

Rear subframe powdercoated with suspension arms (I've installed most of the bushings).
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/_MG_2037.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/_MG_2042.jpg

[RX SE7EN]

Made some good progress this weekend.

The rear is now all clean and sprayed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0557.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0556.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0555.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0554.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0553.jpg

Diff with new bushings:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0552.jpg

The subframe and diff are reinstalled.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0559.jpg


I also relocated the fuel filter. I'm using the stock bracket and filter. I just tapped 2 M8 holes in the rear of the subframe, and ran new hose. Now I just need to get the bracket powder coated.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0550.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0551.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0561.jpg

[RX SE7EN]

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0560.jpg

[mazpower]

Looking good Colin!

[RX SE7EN]

More Powdercoating :) Should all be on the car this weekend.

PPF: added welds too!
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0568-1.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0568.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0571.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0569.jpg

Fuel Pump Holder:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0572.jpg

Oil Pan Brace:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Suspension/IMG_0570.jpg

[JhnRX7]

Colin,

I see your driveline project is coming along nicely... but what is the status of your motor work / twin charge project? I assume you got the oil leak all sorted out? I cant wait to see what this thing does when it is all sorted out!

[RX SE7EN]

Well its a long story. After deals, the car sat for a month, and I stocked up on parts. Then since Brian's garage is full, and we wanted to pull the engine there to fix the oil leak and adjust some of the piping (good to have the welder handy), I decided to tackle the driveline/suspension first.

I should have it on the ground this weekend (as long as I get a delivery from Atomic Rex today), I'll take it to Brian's and we'll pull the motor.

Here's what needs to be done while the engine is out:
-Relocate Throttle Body
-Add Magnusson Bypass Valve
-Add a BOV between Turbo and Throttle Body
-Modify UIM
-New Oil Pan
-New Oil Fill tube with check valve
-New location for PVC
-New Oil Level Sensor
-New Banzai Oil Pan Brace
-Clean up intake piping
-Convert to FMIC (lucky me, I bought a bin of parts 6 months ago, was browsing pics to get ideas for FMIC radiator relocation brackets, noticed a weird bracket that looks familiar, dug through my parts bin, and found all of the Greddy FMIC radiator relocation brackets :) now I don't need to make them myself) Ton's of Win!!
-if we have time spray the engine bay (it's all scratched up)


Then it's test and tune time.

[TitaniumTT]

Engine bay will be sprayed ;) You have to... gotta get the landi out first and that thing is due to leave on a trip on the 11th so we'll be thrashing to get it done, Irene fucked us out of a few good days working on it though.... and now the 'vert and the FC are on stands and the TIG is hanging 3' in the air :rofl:

[RX SE7EN]

Nice, hopefully I get what I need to finish the pillow balls this week, then it will be ready to roll on over for surgery haha.

[helghast7]

holy crap, im back from the dead!

man do i have a lot of catching up to do, how is everyone?

[RX SE7EN]

Doing great over here, about to bleed the brakes!

[RX SE7EN]

Update:

Rear axles and hubs are in.
Subframe braces attached
Fuel lines and filter secured
Brakes installed
Brakes bled
ball joints torqued
tie rod ends torqued
ABS sensors installed

Just need my new toe links to arrive and bolt them on.
Tighten the driveshaft bolts
Torque the PPF nuts
bolt up the exhaust
charge the battery

Then its off to pull the motor!

[RX SE7EN]

Also, finished up the suspension, and dropped the car to the ground for the first time since getting back from deals gap. Sorry for the poor quality, but check it out.

Don't worry, I'll be adding back all of the plastic fender liners, gas tank shield, and fuel line/brake line covers after I clean them up. I'll put those back on after we finish painting the engine bay and get the FMIC and engine in.

Suspension:
http://www.youtube.com/watch?v=NHsPYhnfy3w&feature=relmfu

Undercarriage with relocated fuel filter for easy changes:
http://www.youtube.com/watch?v=PfEqxDch1Ss&feature=channel_video_title

[RX SE7EN]

Here's a quick update, removed the HKS BOV and added a Turbonetics Deltagate wastegate, with its ports plumbed into each side of the throttle body, and its located next to the greddy elbow. This is supposed to allow air to escape everytime i let off the gas, I needed this because my throttle body is between the engine and the supercharger, so if I'm under boost, and let off the gas, the supercharger is still pumping hard (directly linked to the engine), and my throttle body plates are closed. This was stalling out the supercharger and making the belt slip on decel. The wastegate should let air out smoothly to help with normal drivability.

How it looks now is not how it will be after a few weeks, this is just to test and make sure it works.

I was going to test it, but my battery is dead :(
http://www.youtube.com/watch?v=_iqYRxTel4M&feature=relmfu

[WankelsRevenge]

Not getting any images, and an error message saying somethign about video not working... any hope for pictures?
Ryan

[RX SE7EN]

Posted the links, i can't get the videos to work in here for some reason.

[RX SE7EN]

Started on the new manifold, going to mate it to a Q45 throttle body.

I started off wanting to keep the basic layout of the stock UIM, clean up the inside and replace the top with a flat plate of aluminum. Since it's supercharged, I don't really need all of the runners and cross pulsewidth/resonance stuff that is built into the UIM.

It started off looking pretty neat... And yes, I like the grind, hammer, and pry method of demolishing cast aluminum :)

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0585.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0586.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0587.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0588.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0589.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0591.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0592.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0594.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0595.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0597.jpg

[RX SE7EN]

Decided I wanted more room than the stock shape would allow (supercharger inlet is directly below stock throttle body), so I decided to cut some more off and make the plenum volume larger, while still shortening everything up.

So I chopped off everything but the short runners that connect to the LIM.
Threw away this:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0649.jpg

Ended up with this:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0637.jpg

Took a 12" long piece of 3" pipe and cut a little less than 1/2 of a side out. Then I cut some holes so that I could mate it to the remaining piece of the UIM:
Pipe with holes:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0635.jpg
After a lot of grinding it will mate to this:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0639.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0640.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0641.jpg

After lots of grinding and filing:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0642.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0643.jpg

Pretty sweet fit!
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0644.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0645.jpg

[RX SE7EN]

Cleaned and ready for welding:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0646.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0647.jpg

Welded:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0651.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/Twin%20Charger/IMG_0653.jpg

I'll smooth those welds out for the best possible flow.

Now that I've got that done, I'll take the one on the car off and bolt this piece up in order to determine what the rest of it will look like.

[JhnRX7]

:):icon_tup:

I like where this is going!

[RX SE7EN]

Started on the FMIC tonight. Used the greddy brackets to move the radiator, and making custom brackets and piping for my PFS large SMIC which is now going to be a FMIC.

How it used to look:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/PFS%20intercooler/photo.jpg

In Progress:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0655.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0654.jpg

Getting the position right:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0656.jpg

From below:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0657.jpg

I'm going to run the piping a little different than how the usual FMIC kits run, it should look pretty cool.

I really want to switch to a slimmer fan setup so I have more room for some fresh air ducting to the air filter, anyone have any recommendations?

[TitaniumTT]

TORQUEFLO BABY!!!!!!

I should have a stock Cherokee fan that we could try, or something else OEM would be the way to go.... actually, I may have a spal too that you could use for mock up, we'll look when you come by on wed for some welding

[reddozen]

I'm loving the idea. I was wanting to twin charge my FC... hadn't gotten that far yet.

How's the M45 working out for you / going to work out for you? I would think that would be a little small. I have an M90 on the shelf that I was planning on using.

[RX SE7EN]

I've got an M62, should allow me to hit 500 (I hope)

[RX SE7EN]

TORQUEFLO BABY!!!!!!

I should have a stock Cherokee fan that we could try, or something else OEM would be the way to go.... actually, I may have a spal too that you could use for mock up, we'll look when you come by on wed for some welding

Sweet, I'm going to try just cutting the plastic support (upper passenger side in front of the turbo) off and see if it still works ok. I have a feeling it'll be fine, there will still be 3 other 1" think arms holding the fan in place.

Last night i was researching slim fans, nothing flows even close to the stock ones (2700 CFM) unless I go over $150, which isn't worth it right now. We might need to get creative on the turbo inlet, not sure yet.

And I heard bad things about SPAL, didn't your last one fail too? That scares the crap outta me.

[RX SE7EN]

Oh, and you have finally won, I am in the process of ordering -16 AN bungs and fittings for the Rad.....

[RX SE7EN]

So I chopped off the support that was in the way, it's still extremely sturdy, so i don't think it'll be a problem. Now I have plenty of room.

Before:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0658.jpg

After:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0659.jpg

Of course, now the hardlines for the dual oil coolers are in the way. If you remember from a few pages ago, I had to convert the one that went from the driver side cooler to the rear of the block to a -10AN line in order to clear the supercharger bracket. I left all of the other ones stock in order to save money. Looks like I'll be making the rest of the lines match now (it's ok, I was planning on it anyway).
Here's a another pic, now with the oil cooler lines removed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0662.jpg
Notice all the space I have in front for the intercooler to be tilted forward slightly, alowing for softer bends on the piping. Don't worry, this will all be very well ducted.

Also removed my ABS to make room for the catch tank and new oil fill neck. These will share the turbo drain line.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0660.jpg

Firewall is looking better already:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0661.jpg
I'll be using Alex Rodriguez's nifty kit to run the new brake lines with proportioning valve.

[helghast7]

badass, makin some great progress, cant wait to see her when shes done

[RX SE7EN]

Added a mounting tab to the intercooler for its test fit (only tacked on right now). It turned out pretty well, so now I'll add two more tabs to secure it in place.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0672.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0673.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0671.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0676.jpg

Lots of room for piping, and it's slightly tilted so I won't need 90 degree entries into the cooler:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0674.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0678.jpg

With the bumper on. The ductwork will connect it to the bottom of the radiator, and fresh air will go around the sides and directly into the radiator, with ducting to make it so it can't escape before it hits the radiator.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0677.jpg

[RX SE7EN]

Also made progress on the plenum. Had the the top and a side welded on, have the other side cut already but wanted to test fit it first. Note the beautiful welds by TitaniumTT. (i left the side long on purpose in case i wanted to change the angle of the throttle body, i'll trim it off later on)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0666.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0667.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0669.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0670.jpg

Installed, you can see it's really going to clean up the top of the engine, and at the same time give me more plenum volume and allow me to change the oil filter without removing it!
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0679.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0681.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0682.jpg

Not quite as much clearance between the bottom and the supercharger inlet as I'd like, so time to trim it down. This is why you test before welding it all up :)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0680.jpg

Cut line:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0685.jpg

This is the 1/2" plate that will be cut to make the flange for the 90mm throttle body. This will be welded to the front of the plenum and will have 4 holes drilled and tapped for mounting the throttle body. Also got a gasket to seal it up.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0683.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0684.jpg

[RX SE7EN]

The build continues this weekend with new arrivals from Summit Racing :)

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0686.jpg

Whats inside?
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0687.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0688.jpg

A whole bunch of AN fittings, hose, and weld on bungs (steel and aluminum).
Sizes are:
-4 for catch can
-6 for coolant circulation connection between bottom of radiator and fill neck
-10 oil lines and oil fill neck (some will be nylon braided, and i got Stainless braided for the turbo drain which will be covered in black fireflex hose to protect it from the heat
-16 fancy radiator hoses :)

I have weld on bungs for all of that. And I also got a bunch of weld on NPT females for the new plenum, this way my AIT and meth nozzles will screw right in.

Also got a -4 check valve for the meth system. The pump has a built in one, but i wanted to ensure against boost leaks at 12psi when the pump isn't on yet.

[RX SE7EN]

Quite a few updates.

Radiator is done, just need to make some nice looking mounting brackets:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0693.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0694.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0695.jpg

Found a date on it, but not a brand. Does anyone know what kind of radiators PFS used back in the day?
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0697.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0696.jpg

Mounted:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0719.jpg

Room for the piping:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0721.jpg

Room to get at the air filter:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0722.jpg

[RX SE7EN]

Just about done with the manifold.

Welded the bottom plate on at the runners.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0690.jpg

Which got it all nice and hot so I could bend it down:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0691.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0692.jpg

Perfect fitment:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0698.jpg
A piston doing it's job and providing support haha
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0699.jpg

Cut the throttle body flange:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0701.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0702.jpg
Very glad that I bought the 6.5 amp saw

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0703.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0705.jpg

Flush on every side :)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0706.jpg

Ready to cut:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0707.jpg

[RX SE7EN]

Started cleaning up the throttle body and getting rid of stuff I don't need.

This isn't a Nissan:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0708.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0709.jpg

I won't be having any coolant running through this:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0710.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0711.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0712.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0713.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0714.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0715.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0716.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0717.jpg

Now just need to file it smooth.

[RX SE7EN]

Just about done with the new intake plenum!

Took the throttle body flange I cut out and drilled the center hole for the air to pass through:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0705.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0739.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0740.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0741.jpg

Took a while to cut but made it through.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0742.jpg

Perfect port match, no filing needed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0743.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0744.jpg

Drilled and tapped the mounting holes:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0745.jpg

Welded the flange to the plenum:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0746.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0747.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0748.jpg

[RX SE7EN]

Bolted up:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0749.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0750.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0751.jpg

Inside:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0752.jpg

Mounted:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0760.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0761.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0762.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0763.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0764.jpg

Notice the easy access to the oil filter and all of the clearance I have.

Now all that's really left on this piece is to weld on a few bungs for temp sensors and pressure sensors, and also a throttle cable bracket. But I need to figure out where I'm putting all the accessories first (wastegate solenoid, map sensor, fuel pressure regulator, etc... I'm trying to keep it all pretty consolidated)

[RX SE7EN]

Also finding myself having to redo a few things. The radiator and thermostat housing bungs just don't line up well enough with the fittings on. So I'm relocating them. Since I'm making my own AST, I don't really need the capacity of the thermostat housing, so I chopped it off, and now I'll weld a flat cover on it and then add a -16AN bung coming straight out of it. This will go to the top of the radiator.

Chopped up this piece that I've spent a lot of time on, but that happens I guess.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0755.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0754.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0756.jpg

I'll clean up the top of the water pump housing too, and add the -16 bung to it, and also delete all the old nipples that are pressed into it. And a -10 bung for the heater core hose.


I also had to give myself more room for the piping to bend gradually coming out of the FMIC, so I had to go straighten out the brackets to make it completely vertical. This will make ducting a lot easier, and smoother bends for the piping.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0758.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0757.jpg

More updates coming soon!

[TitaniumTT]

Damn dude.... you got a lot done after I took my sick ass home to go to sleep :rofl:

For the T-stat cover.... I should have a length of the pipe left over that I used... Ordered a foot, and used 2" I think....

[RX SE7EN]

Treated myself to a day off of work to work on the car yesterday. Got quite a bit done!

Finished up the thermostat housing and waterpump housing, cleaned it up quite a bit.

Cut a piece out of the left over 1/2" plate that I used for the throttle body flange, drilled the mounting holes and then drilled a hole in the center for the hole saw:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0772.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0773.jpg

Hole saw action:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0774.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0775.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0776.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0777.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0778.jpg

And a -16 AN bung
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0780.jpg

[RX SE7EN]

Cut and ground down a lot of the water pump housing. Now I've got a -16AN for the lower radiator hose, -10AN for the heater core hose, and a -4AN on top for the new AST. I also added a 1/8npt bung to relocate the sensor for my gauge.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0781.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0782.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0783.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0784.jpg

Installed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0789.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0788.jpg

Everything still clears:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0787.jpg

Here's my custom AST, made out of a $20 catch can from ebay, a few bungs, and a billet pressure cap holder.

What it started as:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/RT-OCT-C-SL-1.gif

What it is now:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0785.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0786.jpg

[helghast7]

what made you decide to keep the AST?

[RX SE7EN]

Also have the intercooler in its final location. Soon to be tied down with M8 x 1.25 RivNuts and socket cap bolts.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0802.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0801.jpg

This layout is going to look amazing:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0790.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0791.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0793.jpg

Shortening the bends that couple to the intercooler:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0794.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0795.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0796.jpg

You can see them poking up here:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0797.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0798.jpg

The supercharger outlet/FMIC inlet pipe will run right next to this one:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0799.jpg

[RX SE7EN]

Had to trim the mount on the supercharger to clear the intake pipe:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0803.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0805.jpg

Pretty close to what it will look like:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0800.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0804.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0804.jpg

[JhnRX7]

DIBS on first ride at DGRR!!!

[speedjunkie]

Damn, this thing is gonna be nasty. I love the fabrication alone. I really hope to be this skillful someday. Well done!

[RX SE7EN]

Yeah, me too haha, Brian sure can weld. I feel like I'm getting pretty decent at designing, cutting, and prepping everything, but the welding is what really brings it all together. Plus, two heads are better than one, it's always good to have input on the design of all these pieces. It's truly a tag team effort haha.

[helghast7]

thats for sure, hes always been my go to guy for all my welding/fabing/idea needs lol i wished that he was ready to jig up manifolds at the time i had mine done, not that theres anything wrong with mine, im just the faithful return customer kind of guy

[RX SE7EN]

wire relocation has started:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/wiring/IMG_0813.jpg

Anyone have any idea why my new harness' relay box is different than my current 94 R2?

94 R2 in my car:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/wiring/IMG_0824.jpg

My new harness being modified, with the cover from the 94 R2 relay box seen above. Take a look at the difference between the Air Pump relay sections. Mine has one big relay, the new one has a place for 2 small relays.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/wiring/IMG_0825.jpg

[knonfs]

Awesome build!

Makes me wish I had a garage and a TIG :(

[RX SE7EN]

I actually got some work done this weekend.

Anyone that road home with me from deals gap last year knows how much oil I was leaking, so I finally tackled it. I got a new pan, a new level sensor (the wire broke off my old one), and a Banzai Racing oil pan brace.

You don't have to remove the subframe to do this, but I did for another reason, which you'll see pop up later.

First step: remove motor mount nuts and jack up transmission. Then drop the subframe and remove the pan.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0851.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0853.jpg

Be careful when using a battery powered impact driver to remove the bolts. I got this nice new milwakee driver and drill kit and of course the first time i use it i leave it on tighten instead of loosen and break the bolt off imediately.

Luckly, I was able to gouge a little notch in it and turn it by tapping the edge of a flat head screwdriver with a hammer. I was able to get it out far enough to then get some vicegrips on it. That was a close one.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0849.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0850.jpg

Installed new level sensor on new oil pan.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0855.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0856.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0854.jpg

Clean the block and also tap the holes to get any old sealant and dirt out:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0857.jpg

Dimpled rear iron for a little extra adhesion:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0858.jpg

All done (with powdercoated subframe and stainless hardware):
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0862.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0865.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/RX7%20Oil%20Pan/IMG_0864.jpg

[RX SE7EN]

And here is my first attempt at a "how to" video. Be gentle, haha.
http://www.youtube.com/watch?v=lUGvK1yaXBY&feature=youtu.be

[TitaniumTT]

Nice dude.... looks great. Any pics from the top for the rest? I'll see it tomorrow ;)

[Prodigy]

how much was the oil pan, and level sensor... my wire broke too, and my pan might be a bit warped... lol


J.

[RX SE7EN]

I can't remember, I bought it about 8 months ago. Give Ray at Malloy Mazda a call. I think all in the total was around $125, but you should get a brace too. Banzai or Garfinkle.

[RENESISFD]

$125 for both the sensor and the oil pan? I think the oilpan was about $125.00 from ray. I bought one about 1 month ago.


BTW, How does the powder coater clean and sandblast the inside of the subframe and powder coat it? Seems like it would be very hard to get to.

John

[RX SE7EN]

He just puts it in his booth and sandblasts it, anything on the inside that the sandblaster can't get to just retains the factory coating. And then he just flows the powdercoat in it and it coats everything it can get to (at least as much as the sand blaster got). So there are probably a few spots deep inside that are still black, but they aren't visible unless I was to cut it open.

[RENESISFD]

Got ya, Thanks for the reply, that is what I thought.


John

[RX SE7EN]

Here are the pics of the spacer welded on, I still have to grind down the welds to make it smooth:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0885.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0886.jpg

A few welds on the back for strength:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0884.jpg

The old V-band clamp that was trimmed for clearance:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0894.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0895.jpg

Installed, now I have clearance, before, the cutout on the vband was almost touching the LIM: (I was able to keep the two lower studs on the engine, but the top two studs will be changed to bolts so that I can remove and install the manifold without taking the engine out of the car)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0896.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0897.jpg

Now my new vband clamp can sit like this, and won't need a cutout:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0898.jpg

modified compressor housing:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0888.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0889.jpg

Here you can see the powdercoated subframe:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0891.jpg

[RX SE7EN]

And my modified UIM that is almost finished. Still need to grind down some welds and polish it up. Then send it for powdercoat.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0892.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0893.jpg

There won't really be any improvement in performance (maybe a little less heat soak), but it looks damn cool.

[TitaniumTT]

SHOW THE VAC BLOCK!!!! Please?

[RX SE7EN]

^ will do, but for now this will have to tide you over haha.


Almost done with the oil fill neck and fill line:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0909.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0907.jpg

Catch can is almost done, you can see holes on the side for the sight glass, the filter, and also a -4AN bung that connects it to the oil fill neck. So this will act as the ventillation system. I still need to grind down some of the welds. (This can also matches the AST)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0911.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0910.jpg

Fills through the old rear turbo drain:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0906.jpg

-10 AN stainless steel braided line with fireflex insulation over it because it runs right by the exhaust manifold.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0905.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0904.jpg

I now have a 31mm freeze plug hammered into the port on the middle iron where the original fill neck use to be. Now I have tons of clearance for my supercharger inlet.

I also worked on the flanges for the radiator tonight. Now I have flanges all around the radiator to hold the ductwork in place. Now I just need to bend the sheet metal and rivet it together.

[RX SE7EN]

Making some good progress this weekend. Unfortunately I can't work on it today because I've got to go pick up an extra engine and that will take all day.

Also, I'm converting to E85 temporarily, so I need to pick up a few new parts.

It's so nice to actually see it coming together now, before this, I could only really picture it in my head.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0912.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0913.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0914.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0915.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0916.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0917.jpg

[afgmoto1978]

Who makes that air pump delete idler wheel kit?

Thanks

[TitaniumTT]

Tweakit Racing. A MUST for anyone who deleted thier air pump and likes thier bearings

[RX SE7EN]

Yes, a must have, but I guess there were different batches of bearings. Lots of people are having failures within 1000 miles. I'm going to try to get a few back up bearings.

[RX SE7EN]

Just got 2 of these :) for a total of 680 lb/hr and one of the only in-tank pumps on the market warranteed for E85!

http://aeromotiveinc.com/wp-content/uploads/wpsc/product_images/11140.jpg

[afgmoto1978]

NM

[RX SE7EN]

The fruits of my labor from last weekend (I drove over 1000 miles, and moved to a new state and picked up an engine in a different state haha).
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0918.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0919.jpg

Also, made some killer progress on the throttle cable.

Bought a Lokar Midnight series cable 36" long.
http://static.summitracing.com/global/images/prod/large/LOK-XTC-1000HT_NT.jpg

This has different ends than the stock cable, and also a different way to pass through the firewall. Stock has a nifty clip, and this has 2 nuts that clamp it to the firewall. The hole in the firewall is too big for the new cable (the nuts almost slip through it) so I made the stock clip fit the cable, and then clamped the nuts around it.

Stock Clip:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0920.jpg

Shortened:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0921.jpg

Enlarged hole to fit new cable:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0922.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0923.jpg

Will clip into the firewall, and then i'll go to the inside and screw the end nut on to hold it in place:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0924.jpg

Throttle body:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0925.jpg

[RX SE7EN]

Well, making ductwork took a lot longer than expected. Last night I got the passenger side oil cooler duct done. The rest should go a little faster now that I got the hang of it, and the driver side oil cooler will be easy because it's just the inverse of the passenger side.

I also tried to keep the number of pieces to a minimum. The sides and bottom are all one piece, then a top piece with flaps on the side comes down on top and gets riveted to it. I did it this way so that when looking at it from the outside of the car, you only see one piece with nice smooth bends instead of multiple pieces riveted together (you can't see the top piece with the rivets from outside of the car).

First, I mocked it up with cardboard. Then I laid the cardboard out on a sheet of 6061-T6 aluminum, 0.040" thick (it's white because it has a PVC backing) and traced it out:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0926.jpg

Cut it out:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0927.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0928.jpg

Mark lines to show where to bend the sides up:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0929.jpg

Bend the sides on a break:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0930.jpg

Test fit (make sure you test with the bumper on as well):
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0931.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0934.jpg

Trace out a top:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0932.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0933.jpg

Cut the top piece out (one inch longer on each side so you have ears to bend down to rivet to the side pieces:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0936.jpg

Clamp it where you want it, and then drill 3 holes on each side (through both pieces at the same time) for the rivets. I used 1/8" aluminum rivets. This is also just mocked up, I'm going to send the pieces to powdercoat (black), then rivet them together:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0937.jpg

Next up: driver side, and then radiator/intercooler ducts:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0935.jpg

[JhnRX7]

Car is coming together great! Nice job on the ducting... all that cardboard and aluminum brings back memories haha

Consider using some stick on foam where the duct meets the heat exchanger. It will provide a better seal and prevent any wear from metal on metal contact. Also, your bumper looks to have a couple of openings that would be prime canidates for some brake ducts :D

I need to finish up the intercooler duct on mine soon.

[RX SE7EN]

You are alive! haha

Yeah, i will have some serious brake ducts :)

Stayed tuned, our intercooler setups are pretty similar. It's great because the intercooler will get fresh air, and the radiator will also get fresh air. It's like all the benefit of a Vmount, with the good looks of a front mount.

[Roen]

Why supercharger before the throttle body? Why not after?

[JhnRX7]

You are alive! haha

Yeah, i will have some serious brake ducts :)

Stayed tuned, our intercooler setups are pretty similar. It's great because the intercooler will get fresh air, and the radiator will also get fresh air. It's like all the benefit of a Vmount, with the good looks of a front mount.


Yep, Im still in Puerto Rico lol ...going on 7 months now

Exactly. Only downside is that the radiator will still get some of the heated air from after the intercooler, however with the temp difference between the AIT and water temps it is negligible. That and combined with the extra fresh air going to the radiator you will never notice it.

When I get home I will be picking up a Magnihelic differential pressure gauge and I will be using it to measure the pressures in front of and behind each heat exchanger. The greater the pressure difference, the better the cooling performance. My goal is to optimize the flow out of each cooler by creating lower pressure zones. Its not like it needs any improvement, but the engineer side of me wants to do it haha

Im looking forward to these brake ducts of yours... I have something new in the works for brakes myself ;)

[RX SE7EN]

Why supercharger before the throttle body? Why not after?

I'd like to, but show me where you'd fit that arrangement.

[TitaniumTT]

Oh dear lord, don't get Roen started on theorizing stuff :rofl:

[Roen]

TTT - damn you for showing up!

RX SE7EN - So it was a fitment issue rather than preferring pre-TB over post-TB?

[TitaniumTT]

TTT - damn you for showing up!

Bitch, what you talking about bitch.... who do you thinks doing the welding ;)


So when are you gonna bring that Insight down for a dyno ;)

[Roen]

Bitch, what you talking about bitch.... who do you thinks doing the welding ;)


So when are you gonna bring that Insight down for a dyno ;)

I would do it just for shits and giggles.

[TitaniumTT]

See that whopping 17fwhp..... POS had to drop to 3rd to maintain speed on 78 :smilielol5:

[Roen]

Having 2 overdrive gears in a 5 speed means you can cruise in 2nd on the highway!

[RX SE7EN]

Unfortunately not much work got done on the car over the weekend. But it is now sitting in my new garage, ready to get some serious work done this week:

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0942.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0943.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0944.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0946.jpg

Courtesy of the official Deals Gap Service Vehicle, haha

[JhnRX7]

Glad to see your FD fits nicely on a U-Haul trailer. I will be renting one for my trip down to VIR in May.

So were you officially accepted as one of the participants for the Modified Tuner Shootout? Is Brian going to help out in getting this thing tuned?

[Force13b]

Glad to see your FD fits nicely on a U-Haul trailer. I will be renting one for my trip down to VIR in May.

So were you officially accepted as one of the participants for the Modified Tuner Shootout? Is Brian going to help out in getting this thing tuned?

Both time's i've used a U-haul trailer i've had to pull the bumper off or it would hit the front of the trailer.

[TitaniumTT]

Having 2 overdrive gears in a 5 speed means you can cruise in 2nd on the highway!

Owning a honda means you already suck at life.... owning an insight means you should just slit your wrists now ;)

Both time's i've used a U-haul trailer i've had to pull the bumper off or it would hit the front of the trailer.

Bumper was already off and it fit in the back of the Official RX7 Support Vehicle of DGRR so why bother?

[TitaniumTT]

So were you officially accepted as one of the participants for the Modified Tuner Shootout? Is Brian going to help out in getting this thing tuned?

:suspect:

[RX SE7EN]

Glad to see your FD fits nicely on a U-Haul trailer. I will be renting one for my trip down to VIR in May.

So were you officially accepted as one of the participants for the Modified Tuner Shootout? Is Brian going to help out in getting this thing tuned?

Yup, but the thing is I need to have it running by the 15th, so I have time to drive it a little and get it tuned.

If I don't make it, they will have a substitution ready, but I'd love to go, these opportunities don't come along often.

Brian will be the one tuning it haha. I'd love to do it myself, but I don't really have time to practice on it, I'm hoping I get a good learning session out of it though.

I'm also trying to convince him to come with me and do the driving on the track. But he's pretty busy, and there is a local driver in AZ that is familiar with the course and has driven FD's before. So if Brian can't make it then I'll give that guy a call.

I wish I could do it myself, but this upcoming summer is my learning summer, so for me to go out on a track for the first time for this event, I'd lose and be a disgrace to the RX7 community haha.

Both time's i've used a U-haul trailer i've had to pull the bumper off or it would hit the front of the trailer.
Yeah, no need to pull the bumper off as it was already off haha.

It definitely needs to come off unless the angle the trailer is parked at is just right or you have a few 2x4's to ramp it up gradually.

I also took the exhaust off too, as the back of the muffler hangs pretty low and might scrape the ground as the back wheels finally go up the ramps.

[speedjunkie]

It looks pretty good all together. Glad to see this project nearing completion. I want to see what it'll do. I also like seeing ducting projects, gives me some ideas.

[JhnRX7]

Bumper was already off and it fit in the back of the Official RX7 Support Vehicle of DGRR so why bother?

I plan on renting a UHaul trailer to get to a track day down at VIR... I guess I will have to remove my bumper. Minor inconvenience, but not a huge deal.


Yup, but the thing is I need to have it running by the 15th, so I have time to drive it a little and get it tuned.

If I don't make it, they will have a substitution ready, but I'd love to go, these opportunities don't come along often.

Brian will be the one tuning it haha. I'd love to do it myself, but I don't really have time to practice on it, I'm hoping I get a good learning session out of it though.

I'm also trying to convince him to come with me and do the driving on the track. But he's pretty busy, and there is a local driver in AZ that is familiar with the course and has driven FD's before. So if Brian can't make it then I'll give that guy a call.

I wish I could do it myself, but this upcoming summer is my learning summer, so for me to go out on a track for the first time for this event, I'd lose and be a disgrace to the RX7 community haha.


Yeah... Not to say your not a good driver, but this is definitely not the type of event you want to be your first time out on a track. Hopefully you can convince Brian to go, I know he can pilot it to victory! ...and if he doesn't there will be hell to pay :rofl:

So does this mean you will be joining us this year at track events?? :driving:

[TitaniumTT]

I plan on renting a UHaul trailer to get to a track day down at VIR... I guess I will have to remove my bumper. Minor inconvenience, but not a huge deal.

You might not have to... Bring along a bunch of 4' 2x4's and you'll be able to get it up there without a problem.

Yeah... Not to say your not a good driver, but this is definitely not the type of event you want to be your first time out on a track. Hopefully you can convince Brian to go, I know he can pilot it to victory! ...and if he doesn't there will be hell to pay :rofl:

:rofl:

So does this mean you will be joining us this year at track events?? :driving:

If he ever gets the sand out of his vagina... maybe ;)
But he still needs to find some pink racing shoes and some fire retardant pantyhose....

[WE3RX7]

Silly guys towing with XJs...


I fit our lowered RX3 and front splitter on a uhaul trailer with little effort, you should be ok.


Also, why would you want Brian to drive it down the track? If memory serves me correct, the last RX7 he had on the track got him too excited and the result was touching a rotor to the plate :banghead: and that was just a little twin turbo RE, not the monster twin charger REW this beast is housing...:rofl:


Sorry B, it'll be a while before you can redeem yourself and face it, we don't have much to pick on ;)

[JhnRX7]

Also, why would you want Brian to drive it down the track? If memory serves me correct, the last RX7 he had on the track got him too excited and the result was touching a rotor to the plate :banghead: and that was just a little twin turbo RE, not the monster twin charger REW this beast is housing...:rofl:



:smilielol5::lol::lol::lol::lol::smilielol5:

[TitaniumTT]

:rofl: Well, when you have soooooo many gears to choose from ;)

I'm sorry.... when was the last time you had a rotary on the track that made more than 1/2 of what I was making? Silly renni's :smilielol5:

I'll redeem myself with sub ambient intake temps @ DGRR

[Roen]

Owning a honda means you already suck at life.... owning an insight means you should just slit your wrists now ;)

Agreed on the first point, but with gas at what it is, and actually, with what I'm paying ($1.314CAD/L for regular = $4.991 per gallon), I'm happy to get 3.5 L/100 km (67.2 mpg)

Once gas goes sub 3 again......then I'll have fun burning some rotary fumes. :sifone:

You still need to help me with my cheater RX-8 project next year......at least that's when I'm hoping to pick one up. What are the odds of a 2010 model getting down to $15k?

[RX SE7EN]

Got a few goodies in the mail today from one of my sponsors for the upcoming Modified Tuner Shootout. CJ Motorsports is helping me convert to E85, I can't say enough about their products and great customer service.
- CJ Motorsports dual pump holder with custom -8AN return
- dual Aeromotive Stealth 340's
- CJ Motorsports secondary and primary rails
- CJ Motorsport secondary injector spacers (for my modified LIM)

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0947.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0948.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0949.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0950.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0951.jpg

I'll be running -6 braided lines in parallel to each rail (each rail will have it's own pump). And then a -8 return line.

Here is my new fuel pressure regulator to handle all of the return flow without giving me pressure spikes: Fuel Lab 565 series
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/fuelab_56501.jpg

[RX SE7EN]

My garage is a mess due to the move, so after 2 hours of looking for a bolt the other night, I decided I better clean it up and get organized.

The biggest obstacle is the engine crane. I have an engine stand, but no adapter for a rotary. So I had to make one, this will allow me to wheel the engine into the corner on a stand, and fold up the crane. This will give me enough space to put the car on dolleys and spin it sideways and work on it in the middle of the garage with plenty of room to work on it.

Here is how to make a rotary engine adapter for a standard stand.

4 feet of home depot 1/4" thick steel 2" angle iron
A bunch of bolts and some good drill bits.
Angle grinder to cut the angle iron
Drill

Two pieces of angle iron cut, with holes drilled. These both have 3 holes on one side so you can bolt them together. One has 2 holes that bolt to the piece that came with the stand, and the other has 4 holes that bolt to the front iron on the block:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0956.jpg

Here you can see I drilled 2 new holes in the piece that came with the stand. This allows me to center the weight of the engine a little better.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0957.jpg

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0961.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0962.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0963.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0964.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0965.jpg

How much space it was taking up:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0958.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0959.jpg

Decided to tear down the long block. I've never had a stock engine before, now I know why people don't like to work on them haha. Single turbo engines are so much cleaner and easy to maintain.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0967.jpg

Pile of junk (most of it is pretty well cooked):
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0968.jpg

[RX SE7EN]

And since I'm ready to bolt on the water pump housing and water pump and new LIM and fuel system, I figured why not clean the block up a little:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0953.jpg

primer:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0954.jpg

Paint (I know this isn't the nicest way to do it, but i don't have much time before the shootout, and I covered everything that anyone would ever see anyways)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0955.jpg

Once I get all the other pieces powdercoated it's going to look amazing.

[RX SE7EN]

Had a somewhat productive weekend, although I didn't get as much done as I had wanted. Turns out i don't have the right style crimp tool to do the crimps needed for the injectors and fuel pumps. So I need to try to find a good one and order it today.

I did get the cat installed though, had to move the borla resonator back as far as I could, and then the cat fit perfectly.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0982.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0983.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0984.jpg

This will probably hurt my hp up top, but I don't think I'll have the usual negative impact of backpressure causing lag, my supercharger should offset that.

[RX SE7EN]

I also redid the supercharger intake pipe. For last year's deals gap I was running out of time and kept having to hack this pipe up to clear the oil fill pedelstal. I ended up still not getting it to clear and having to bash the piece with a hamer to make it clear.

Now that I've relocated the oil fil, and have the extra clearance from removing the oil fil pedestal completely, and blocking the hole off with a freeze plug, I remade the piece the way it was originally supposed to be. The dipstick was another obstacle, but I made it around it. Even ported it all on the inside for nice smooth flow:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0971.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0972.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0980.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0981.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0979.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0978.jpg


This piece was extremely complex. The clearance at the back of the supercharger was tough, and then the pipe has to curve up between the alternator and UIM to go to the turbo. Space is supper tight there, as the engine block gets in the way (the raised part on the front iron with the two bolt holes on it), as well as the secondary fuel rail being an issue. But I finally got it to work.

I also finished the primary fuel rail/vacuum block. The rail is from CJ Motorsports, and I modified it's spacers to hold my vacuum block. This vacuum block has one -6 AN bung that connects to the UIM, from here, all -4AN lines spider out to everything else (boost controller, FPR, blow off valvle, etc...), and one -6 AN line to the brake booster.

This started off as a 1 foot long 1.5" square piece of aluminum stock. All machining done by my trusty drill and sawzall and when that died i toughed it out with my hack saw haha.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0974.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0975.jpg

[RX SE7EN]

And the piping is done :)

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0976.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0977.jpg

who wants a twincharger kit? haha

[speedjunkie]

So I assume you're nearing the end of this project, correct? I've been following the thread and this is one of those things I'd never have the guts to take on lol. Nice work and I can't wait to see it finished and see what it'll do.

[RX SE7EN]

Getting pretty close. The major fabrication is done. Now it's just some wiring, porting all the rough edges in the piping, making AN lines, brake lines, vacuum lines, cleaning stuff up and bolting it together.

Then a little body work on my r magic fenders too. i sure hope it works haha.

[RX SE7EN]

Made some decent progress today. Dropped the powdercoated alternator housing off at IRP and their alternator supplier is putting 140amp internals into it next week.

Finished my oil fill and catch can, I love it:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1005.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1006.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1007.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1008.jpg

Cleaned the brake booster up, drilled out the vacuum nipple, painted it, and installed the -6AN check valve for a much cleaner look:
Drilled, Cleaned, and Primed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0999.jpg

Painted:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1001.jpg

-6AN check valve installed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1002.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1003.jpg

Worked on the fuel system, manged to get the old spacers and diffusers out, and swapped in these fancy O-ring style spacers from CJ Motorsports. Using the same for the secondaries too:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0997.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0998.jpg

[RX SE7EN]

Out with the old and in with the new (new is the twin setup, old is the Aeromotive Tsunami). This moves me from 500whp capacity to about 700.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0990.jpg

Pics of the Hyperion fuel anti-surge cover:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0991.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_0992.jpg

Should do the trick when I finally make it to the track.

[RX SE7EN]

It's crunch time for deals gap, so I've been pulling some long nights during the week. The engine bay is pretty much back together.

The new LIM is installed and looking pretty, here is a side by side comparison of what I turned the stock one into:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1009.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1010.jpg

Also, here is my version of a sweet vacuum line. This is a -6AN line for the brake booster, all other lines will be -4AN. Please note that you can't just use any braided hose, it has to be rated for vacuum (not many are).

Bare hose:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1017.jpg

Raychem (deisel retardent milspec heat shrink for wire harnesses), this will make sure the SS hose never rubs through anything, and also keeps the theme by being black (using Raychem is overkill, but I have a lot of it, and this is non-name brand anyways). I had to use SS because the braided nylon hoses available are not raided for vacuum.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1019.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1018.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1020.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1021.jpg

Seal the ends with 4:1 adhesive lined heat shrink:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1022.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1023.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1024.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1025.jpg

This is good prep for making the wiring harness this weekend haha.

[RX SE7EN]

Also cleaned up the radiator and it's brackets. Then I painted them black with VHT Epoxy paint. I wish I had found this type of spray paint a long long time ago, it's soo much tougher than anything else I've used.

This will all be powdercoated eventually, but don't have time before deals gap.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1026.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1027.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1028.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1029.jpg

[FerociousP]

That epoxy is good stuff... I touched up some rust on my truck with it and it matches the 20yr old (now satin) paint perfectly. I also used it on chassis components like the sway bar and skid plate, etc. Really nice clean looking black without being to glossy.

[RX SE7EN]

Got my 929 master cylinder. Machined the one port flat so I can use banjo bolts on both of them (to save space in the area). Then painted black of course.

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1030.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1031.jpg

This will keep the pedal feeling good for the BBK

[calicrewchief]

Great work and progress! Where could I find one of those check valves for the brake booster?

[RX SE7EN]

Jegs has them.

[RX SE7EN]

Worked on the fuel lines today. Had to get special low profile 90 degree -6 and -8 hose ends for them to clear under the fuel panel in the back.

Then I went to work on covering them so they can't rub on anything. This is all E85 safe SS fuel line. Two -6 feeds and a -8 return.

Plain line:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1040.jpg

Black heat shrink for protection, then labeled for future convenience, and clear adhesive tubing over the ends and labels:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1037.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1038.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1041.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1042.jpg

Also made the duct for the radiator. Fits the bumper perfect, and then tapers to the radiator. the FMIC sits square in the middle of the bumper, so anything that gets around the sides goes straight to the radiator. I'll redo this later on with a single piece of aluminum. It will be easy to make now that I've got this as a template.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1045.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1046.jpg

Not many front mounts of a decent size let fresh air get to the radiator :)

[RX SE7EN]

I had IRP upgrade my alternator. I had dropped off my powdercoated housings last week and picked up the upgraded unit yesterday. All bolted on:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1039.jpg

A few shots of it coming together:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1036.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1035.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1034.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1033.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1032.jpg

Still a lot to do before deals gap though. Going to be a long week.

[WankelsRevenge]

When this engine is done and complete, it will deffinatly be added as a background on my computer.

[JhnRX7]

Not many front mounts of a decent size let fresh air get to the radiator :)

I can think of one :p

Ducting looks good, and I love the labeled lines :icon_tup:

[RX SE7EN]

Thanks John,

Unfortunately this week hasn't gone very well so far though. Everything seems to be taking forever. I'm taking tomorrow off of work, and working all weekend on it. That's 3 solid days to do the following:

Must do's:
Make the fuel lines
Make the brake lines
Make the coolant lines
Make the vacuum lines
Mount the wastegate solenoid
Mount the MAP sensor
Mount the EGT sensors and signal box
Relocate meth pump (duct work is now in the way)
Make one more oil cooler duct
Port all the piping (smooth out rough edges)
Add ICV to the plenum
Remove the dash, finish the new wire harness, install it, re-install the dash
Add oil
Add coolant
Get tuned (Monday night I hope)

Like to do's
Add brake ducts
Install BBK
Make A/C lines

I need to have a productive 3 days.

[budfc3s]

best of luck the car is coming out sick cant wait to see it on the dyno!!!!

[Oyvindjs]

cant wait to see the graphs of this engine! :) Good luck on your work! :)

[legatia]

I feel so bad for surfing the forums right now.. Garage keeps screaming my name!
Looking good

[RX-7FD3S]

god damn, this is one sexy project, keep it up :)

[TXRota]

O lord...no lag on a rotary, especially a 3rotor = ass whoopins

[general7]

That looks amazing, def checking back here for progress!

[RX SE7EN]

All nighters are synonymous with DGRR haha.

Decided to hold off on my milspec wiring job, not enough time to have it back up and working unless I cut corners. So I decided just to relocate the fuse boxes in the engine bay (the new piping is now where they used to mount. I'm also cleaning the old wiring up a lot. So it's not quite what I want, but its a huge improvement and I'll eventually redo it and tuck it all inside after DGRR.

The mess:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1064.jpg

Cut off:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1066.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1065.jpg

Tefsil Wire:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1069.jpg

New lengths added:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1067.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1070.jpg

4 to 1 adhesive shrink insulation for the uninsulated crimps:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1071.jpg

3 to 1 shrink wrap:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1072.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1073.jpg

Still need to fab up a bracket to actually hold it.

Also extended the fan wires in a similar fashion, as well as ran new wires for the coils. Now all I have to do is add the new clips for the injectors and extend a few sensors.

[RX SE7EN]

New fuel line holder for my 3/8" SS twin feed lines, and 1/2" return line:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1062.jpg
Still holds the rear brake line in place.

Making the lines:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1060.jpghttp://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1059.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1061.jpg

Also, a new idler pulley, ceramic ball bearing sweetness:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1063.jpg

New spot for my new FPR: It's too massive to put on the firewall.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1051.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1052.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1053.jpg

Custom clutch line to hide it better and save space:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1048.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1047.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1049.jpg

[RX SE7EN]

Finally started it. Was troubleshooting wiring for a long time because my spark and fuel injectors weren't firing. I had decided to move the switched 12V source for my ECU to the open slot on the top right corner of the fuse box by the clutch pedal.

All my wires were checking out ok, continuity everywhere it was needed and 12V sources and grounds were good. Just no signal going to anything. Checked my crank sensor, the wires and resistance were good.

Then I looked at my ECU while I was cranking and noticed the LED's turned off and it would disconnect from my computer while I cranked. So I determined it was loosing power when I went to start it. Then I remembered I had changed the switched power source. So I changed it back to where it was, which was just highjacked off of the stock fuse for the fuel pump. And bam, it fired right up. So must be the top right 12V port of the fuse box looses power when the key goes to the "Start" location.

It won't really idle yet, I've got to adjust the throttle body idle screw and the new larger injector settings. But it sounds pretty good. I also need to tighten down the turbo's vband flange.

Here's the video, please ignore my excited friend haha.
http://www.youtube.com/watch?v=gjr11AYlhLE&feature=youtu.be

[TitaniumTT]

You suck... couldn't wait ONE MORE DAY!?!?!?!

Been there, done that with the wiring... did it just 2 days agao actually with the rustang that I blew the mufflers up on :smilielol5:

[RX SE7EN]

Haha, just be glad, now you can come over and help me get it to idle right. Then we can rip it apart and send stuff to powdercoat and redo the wiring haha.

[TitaniumTT]

:smilielol5: Wait.... didn't it JUST GET BACK TOGETHER!!!!!

[Oyvindjs]

grats on start! Will be fun to see some numbers on this build :D

[Sharingan 19]

Awesome project! Way to see it through, now for that startup vid....

[RX SE7EN]

Started on the wiring. Moving all relay and fuse boxes to the rear bin. Also adding a fuse box and relay boxes for the ECU and auxiliary functions such as gauges, alarm, radar detector, etc...

Big piece of plastic (so I don't have to worry about using metal that could arc with any wires that get damaged (not that there should be any of those, but just in case).
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1084.jpg

Trace the design, and cut:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1085.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1088.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1086.jpg

Mount boxes:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1087.jpg

Mount inside the car, and make sure it clears the rear bins, so they can be reinstalled.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/FMIC/IMG_1089.jpg

The dash is out of the car, and now I'm just running all the wires and connecting everything up. My driver side door lock actuator and Viper alarm system should be in this week. I'm also going to try to hook up an actuator to the trunk latch so I can use the auxiliary on the alarm remote to open it.

[RX SE7EN]

I just sold my yellow top battery to try to save some space now that my battery will be in a box in the hatch instead of in the bin.

I'm thinking about this one:
http://www.summitracing.com/parts/ODY-PC925MJT/
http://static.summitracing.com/global/images/prod/large/ody-pc925mjt.jpg

Is 380 cold cranking amps good enough for a street car?

There is a cheaper version available with the same specs, but this one has a metal casing on it and better resistance to vibration (supposedly)

Are there any other specs that I should pay attention to? I have a small amp and sub, but not any kind of crazy system or anything. My alternator has also been upgraded to 140amps by IRP.

[infernosg]

Argh, over $200 for a battery! You may want to look into the ETX..L batteries. I picked up a Deka ETX18L for less than $90. 340 advertised CCA, 18 lbs, and 6" x 3" x 8".

[RICE RACING]

I just sold my yellow top battery to try to save some space now that my battery will be in a box in the hatch instead of in the bin.

I'm thinking about this one:
http://www.summitracing.com/parts/ODY-PC925MJT/
http://static.summitracing.com/global/images/prod/large/ody-pc925mjt.jpg

Is 380 cold cranking amps good enough for a street car?

There is a cheaper version available with the same specs, but this one has a metal casing on it and better resistance to vibration (supposedly)

Are there any other specs that I should pay attention to? I have a small amp and sub, but not any kind of crazy system or anything. My alternator has also been upgraded to 140amps by IRP.

I have been using Ody PC535 for the last 8 years! on RICESP.

Much smaller, much lighter, much lower CCA, and it cranks it totally perfectly!

I recently bought a spare battery and shipped here from USA to my door it was like $150Au.

You can see the size of my battery in my car build up pics, it fits in my carbon battery tray along with 3 CDI units and integral holder. I love it, its the best battery I have ever used/owned.

I found out about it through a local rally champion who was using the same unit.

[RX SE7EN]

Haven't had too much time to spend on the car lately, but am making some progress on the wiring.

I've got the interior stripped, and the stock harnesses just about completely modified and reinstalled. Now I've just got to add in the alarm and wiring for the ECU.

New panel to hold the relay and fuse boxes in the rear bin:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1084.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1085.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1086.jpg

Here you can see the new fuse box and relay boxes for the ECU and auxiliary components
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1087.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1088.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1089.jpg

Best wire stripper I've ever owned.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1096.jpg

New crimper for weather/metri pack type connectors, here I'm crimping terminals for the wires that go to the relay boxes that will control outputs of the ecu (fuel pumps, coil +, injector +, supercharger, exhaust cutout, etc...)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1099.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1098.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1100.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1101.jpg

[RX SE7EN]

Part of the reason why I decided to rewire the ECU: (not very tidy)
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1102.jpg

To tuck everything in the engine bay, I decided to put all relay and fuse boxes into the rear bin. To start, I took out the front body harness (the one that wraps from the driver side foot well, around the front of the car, and into the passenger side foot well).

Identify the plugs you don't need in the engine bay and snip the wires, then snip the same wire at it's other end to delete the wire completely. For example, I'm deleting the fan relays and using my ecu to control the fans, so I snipped every wire at the relay, then I went and snipped the other end of the wires at the relay and fuse boxes and another other plugs they went to.

Label each wire that you are keeping but relocating (all wires going to the relay box got an "R", all wires going to the Fuse box got an "F". There are other wires that go to the large Grey connectors next to the fuse box, I gave these all numbers.

The last few wires left just run from the driver side foot well to the passenger side foot well. I labeled these all with a number as well. After snipping these off, I ended up with a driver side harness and a passenger side harness. There are barely any wires left on the passenger side. and the ones that connect to the driver will now be connected inside the car, instead of wrapping all the way around the front end.

Stripped harness, being labeled and cut:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1103.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1104.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1105.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1105.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1113.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1114.jpg


Everything cut except for the 6 remaining wires that just run from foot well to foot well:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1116.jpg

You can see the bulk of the wires end up on the driver side:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1117.jpg

Once it's in two pieces, put it back in the car and connect the remaining connectors to the fuse box by the clutch pedal and all of the other connectors down there. Once you know where all the connectors go, tape it all off so that the it all fits nicely and each wire goes where it's needed. Then remove and completely wrap it.

Driver side, wrapped up. Now the wires that run to the rear of the car for the relay and fuse boxes need to be extended and wrapped.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1118.jpg

This is the hardest part, now I just need to run the new wires for the ECU and alarm system.

[RX SE7EN]

Finally got all of the wires into the bulkhead.

Here is the engine bay side, took a while to braid everything, everything has been left long, I won't trim it down and cover it until I have it in the engine bay.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1159.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1160.jpg

Yes, that is an 8 wire braid, I surprised myself on that one haha.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1161.jpg

Used almost every terminal available
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1163.jpg

Here is the side that will sit inside the car. This will connect to the TEC GT ecu, plx gauges, stock gauges and indicator lights, and a few other wires on the stock body harness.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1162.jpg

Now i just need to put the strain reliefs on, the Raychem, and then the connectors.

Oh, and it's now wired for 8 injectors and 8 coils, just in case I ever save up for a 4 rotor haha.

[Mitchocalypse]

Nice job. clean wiring like that is so much easier to work with and looks hundreds of times better. Love the uniqueness of this build

[knonfs]

Looking good!

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1098.jpg

Is that the same tool used for the weatherpack connectors?

[RX SE7EN]

Yes, that's a GM/Weatherpack style crimper. That was used for the relay boxes, not the milspec bulkhead. The milspec pins are barrels that use a Deutsch style terminal. A special, expensive crimp tool is used for those (but I save $100 and got mine used on ebay for $70 and it works like a champ)

[knonfs]

Yes, that's a GM/Weatherpack style crimper. That was used for the relay boxes, not the milspec bulkhead. The milspec pins are barrels that use a Deutsch style terminal. A special, expensive crimp tool is used for those (but I save $100 and got mine used on ebay for $70 and it works like a champ)

SWEET! I have one of those relay boxes (not installed), plus I want to redo the wiring harness on the fc. Off to ebay in search for a weatherpack crimper.

[RX SE7EN]

Finally got my deutsch connectors in. Now I can finally finish the body harness and start hooking things up.

I wanted black ones, but then I cheaped out and went with the Grey, still cool though.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1164.jpg

Milspec crimper, used for these connectors as well as the milspec bulkhead:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1165.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1166.jpg

[RX SE7EN]

Got the firewall ready for the bulkhead today. The old hole that the wires went through it much larger than the bulkhead, so I made a filler out of steel:

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1167.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1170.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1171.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1172.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1173.jpg

And test fit before painting it:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1169.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1168.jpg

Tomorrow the paint will be dry and I'll install it. I'm going to use 5 rivets to attach it to the firewall, but with some black silicone (Permatex "Right Stuff") between it and the firewall to seal it all up.

Once thats done, I can start connecting everything up on the inside of the car, and maybe get the dash back in tomorrow if all goes well.

[RX SE7EN]

Well, I'm getting there. Spent a ton of time on it this weekend, but ran into a few hickups that slowed me down a lot. (you may have seen my other threads on A/C and Tach wiring that detail my problems). I've got it sorted out now though, so full speed ahead.

I've got the firewall and ECU harnesses just about done now:
Dash Harness: Connects engine harness bulkhead to dash, gauges, ECU, relays, etc...
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1194.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1193.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1198.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1192.jpg


How I keep track of everything, every connector and wire is logged into my master master wiring excel file.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1195.jpg

The ECU harness is just about done (looks very similar to the firewall harness above.

I also have the rear of the car almost complete with the relay and fuse boxes almost complete (same style with Deustch connectors.

[FerociousP]

what kind of clear shrink is that? In the last pic it looks very thick.

[RX SE7EN]

4 to 1 adhesive lined heat shrink. that's why it's so thick.

[ROT8WA]

Easiest way to braid wires that I have found is to secure one end in a Vice and tape the other end to a drill, then its a simple as squeezing the trigger. It'll save your thumbs. I remember helping out with the wiring on a M&W ignition and using my Thumbs at the beginning really munged Buttox.

Good Stuff build wise man, massive undertaking. Hope it meets your expectations.

Finally got all of the wires into the bulkhead.

Here is the engine bay side, took a while to braid everything, everything has been left long, I won't trim it down and cover it until I have it in the engine bay.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1159.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1160.jpg

Yes, that is an 8 wire braid, I surprised myself on that one haha.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1161.jpg

Used almost every terminal available
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1163.jpg

Here is the side that will sit inside the car. This will connect to the TEC GT ecu, plx gauges, stock gauges and indicator lights, and a few other wires on the stock body harness.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1162.jpg

Now i just need to put the strain reliefs on, the Raychem, and then the connectors.

Oh, and it's now wired for 8 injectors and 8 coils, just in case I ever save up for a 4 rotor haha.

[RX SE7EN]

Just about got all of the relays and fuses done. Just need to hook up a few more wires, and then the rear of the car is all set. Once I'm sure its good then I can put the dash back in.

This panel fits in the passenger side rear bin. I'm not sure if I'm going to put the battery in the drivers bin or in the trunk yet.

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1201.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1203.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1202.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1204.jpg

One question on the fuse box for the experts out there. Should the buss for the Ground be hooked to the battery negative terminal, or should I go to the chassis ground?

[RX SE7EN]

A few small updates. Just about done with the engine harness:

Completely sealed:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1209.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1208.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1210.jpg

Raychem boots:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1207.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1205.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1206.jpg

I'm waiting on some new injector clips, then I can finish it up.

[RX SE7EN]

Getting closer, I need to get a few more clips and then pop them on. Everything is all cut to length now, pretty much done.

Notice how everything is labeled, and on the parts that already have the clip installed, they are completely sealed, you can't see any of the wire sticking out of the back of the clip/connector.

I also doubled up with some heavy duty adhesive lined heat shrink on the raychem boots. I couldn't tell if they were really sealing, but with the extra adhesive heat shrink over the ends, you can see out the adhesive has seeped out, its sealed for sure now.

http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1215.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1216.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1217.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1218.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1219.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1220.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1225.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1224.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1223.jpg

This connector is for 4 extra injectors. It will remain capped off until i need them.
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/ECU%20Wiring/IMG_1221.jpg

[speedjunkie]

Damn. You should make one for me too lol. That is just sexy, and I HATE wiring.

[TitaniumTT]

Killer job on the harness.... looks BADASS.... and I know your pain all to well with respect to ordering those Raychem boots..... but damn they do look good don't they ;)

[RX SE7EN]

Apologies in advance for the quality of the pics, I really need a new camera, and decent lighting would help too haha.

Stopping power:

Old:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/1D8ACCD6-3623-4996-9A28-1BE2287AC489-1624-000000C8ABAEB1A6.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/7619B1F6-7873-44E1-8BDE-803193FDE8AA-1624-000000C8B5C25082.jpg

New:
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/5E927A61-DE8F-4A8D-903F-B74685A0BDC9-1624-000000C8826DDFD4.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/7732E59D-348F-4653-9636-8CDD2C469FC2-1624-000000C88EE23875.jpg

Old vs new
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/1DCA2314-2D89-427D-B4B0-E9A41F793687-1624-000000C8D2185AAE.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/AB052B72-4283-4464-B90A-7E5631C17DAE-1624-000000C8C9D1F546.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/D371681E-37CC-480F-B134-73E2E7726A7F-1624-000000C8BDC86037.jpg
http://i254.photobucket.com/albums/hh92/Chudsoncoupe/D6901176-351F-4A3D-919C-AA22886FEF54-1624-000000C8C3F4773F.jpg

[JhnRX7]

What are those new calipers? Was that a custom job to make them wider for a larger disk? 32mm wide rotor? What Pads do you plan on running? Is that lettering a sticker or painted on? Looks like a cool setup. Any plans for the rear?

FYI. I had borrowed your idea of printing wiring labels on paper and using it under clear heat shrink. I used adhesive heat shrink for the wire connections, but not on the clear label heat shrink... Mistake. Oil leaked on one of the label areas and it got under the heat shrink and the paper sucked it right up. Rookie mistake. It looks like you did use the adhesive stuff for yours?

[RX SE7EN]

Calipers are Outlaw calipers, an upgraded version of the ones offered with the older Pettit BBK. The rotor is 1.25" thick, and a hair under 13" diameter. It's the absolute biggest that the caliper would allow.

The caliper was sent back to Outlaw and they enlarged one of the piston bores, so now they are slightly offset, helping to even out the brake pressure and pad ware.

To do the lettering I painted the calipers black, put stickers on, painted them blue, and then peeled the stickers off. I should have wet sanded them down a bit, as now there is a bit of a lip between the black base coat and the 3 coats of blue.

The wiring labels were on plastic, adhesive backed labeling. I haven't had any problems yet, but then again i haven't driven my car haha.

[gmonsen]

Nicest wiring I've seen.

G

[calicrewchief]

Any updates?

[RX SE7EN]

Not really, just sent the ecu to electromotive to see if it's working correctly. Car is not getting fuel, but all wires are testing out to the right pins. Once I hear back from them I'll know what to do next.