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Quote:
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. |
Oh, and you have finally won, I am in the process of ordering -16 AN bungs and fittings for the Rad.....
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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/h...C/IMG_0658.jpg After: http://i254.photobucket.com/albums/h...C/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/h...C/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/h...C/IMG_0660.jpg Firewall is looking better already: http://i254.photobucket.com/albums/h...C/IMG_0661.jpg I'll be using Alex Rodriguez's nifty kit to run the new brake lines with proportioning valve. |
badass, makin some great progress, cant wait to see her when shes done
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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/h...C/IMG_0672.jpg http://i254.photobucket.com/albums/h...C/IMG_0673.jpg http://i254.photobucket.com/albums/h...C/IMG_0671.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0674.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0677.jpg |
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/h...C/IMG_0666.jpg http://i254.photobucket.com/albums/h...C/IMG_0667.jpg http://i254.photobucket.com/albums/h...C/IMG_0669.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0679.jpg http://i254.photobucket.com/albums/h...C/IMG_0681.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0680.jpg Cut line: http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0683.jpg http://i254.photobucket.com/albums/h...C/IMG_0684.jpg |
The build continues this weekend with new arrivals from Summit Racing :)
http://i254.photobucket.com/albums/h...C/IMG_0686.jpg Whats inside? http://i254.photobucket.com/albums/h...C/IMG_0687.jpg http://i254.photobucket.com/albums/h...C/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. |
Quite a few updates.
Radiator is done, just need to make some nice looking mounting brackets: http://i254.photobucket.com/albums/h...C/IMG_0693.jpg http://i254.photobucket.com/albums/h...C/IMG_0694.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0697.jpg http://i254.photobucket.com/albums/h...C/IMG_0696.jpg Mounted: http://i254.photobucket.com/albums/h...C/IMG_0719.jpg Room for the piping: http://i254.photobucket.com/albums/h...C/IMG_0721.jpg Room to get at the air filter: http://i254.photobucket.com/albums/h...C/IMG_0722.jpg |
Just about done with the manifold.
Welded the bottom plate on at the runners. http://i254.photobucket.com/albums/h...C/IMG_0690.jpg Which got it all nice and hot so I could bend it down: http://i254.photobucket.com/albums/h...C/IMG_0691.jpg http://i254.photobucket.com/albums/h...C/IMG_0692.jpg Perfect fitment: http://i254.photobucket.com/albums/h...C/IMG_0698.jpg A piston doing it's job and providing support haha http://i254.photobucket.com/albums/h...C/IMG_0699.jpg Cut the throttle body flange: http://i254.photobucket.com/albums/h...C/IMG_0701.jpg http://i254.photobucket.com/albums/h...C/IMG_0702.jpg Very glad that I bought the 6.5 amp saw http://i254.photobucket.com/albums/h...C/IMG_0703.jpg http://i254.photobucket.com/albums/h...C/IMG_0705.jpg Flush on every side :) http://i254.photobucket.com/albums/h...C/IMG_0706.jpg Ready to cut: http://i254.photobucket.com/albums/h...C/IMG_0707.jpg |
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/h...C/IMG_0708.jpg http://i254.photobucket.com/albums/h...C/IMG_0709.jpg I won't be having any coolant running through this: http://i254.photobucket.com/albums/h...C/IMG_0710.jpg http://i254.photobucket.com/albums/h...C/IMG_0711.jpg http://i254.photobucket.com/albums/h...C/IMG_0712.jpg http://i254.photobucket.com/albums/h...C/IMG_0713.jpg http://i254.photobucket.com/albums/h...C/IMG_0714.jpg http://i254.photobucket.com/albums/h...C/IMG_0715.jpg http://i254.photobucket.com/albums/h...C/IMG_0716.jpg http://i254.photobucket.com/albums/h...C/IMG_0717.jpg Now just need to file it smooth. |
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/h...C/IMG_0705.jpg http://i254.photobucket.com/albums/h...C/IMG_0739.jpg http://i254.photobucket.com/albums/h...C/IMG_0740.jpg http://i254.photobucket.com/albums/h...C/IMG_0741.jpg Took a while to cut but made it through. http://i254.photobucket.com/albums/h...C/IMG_0742.jpg Perfect port match, no filing needed: http://i254.photobucket.com/albums/h...C/IMG_0743.jpg http://i254.photobucket.com/albums/h...C/IMG_0744.jpg Drilled and tapped the mounting holes: http://i254.photobucket.com/albums/h...C/IMG_0745.jpg Welded the flange to the plenum: http://i254.photobucket.com/albums/h...C/IMG_0746.jpg http://i254.photobucket.com/albums/h...C/IMG_0747.jpg http://i254.photobucket.com/albums/h...C/IMG_0748.jpg |
Bolted up:
http://i254.photobucket.com/albums/h...C/IMG_0749.jpg http://i254.photobucket.com/albums/h...C/IMG_0750.jpg http://i254.photobucket.com/albums/h...C/IMG_0751.jpg Inside: http://i254.photobucket.com/albums/h...C/IMG_0752.jpg Mounted: http://i254.photobucket.com/albums/h...C/IMG_0760.jpg http://i254.photobucket.com/albums/h...C/IMG_0761.jpg http://i254.photobucket.com/albums/h...C/IMG_0762.jpg http://i254.photobucket.com/albums/h...C/IMG_0763.jpg http://i254.photobucket.com/albums/h...C/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) |
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/h...C/IMG_0755.jpg http://i254.photobucket.com/albums/h...C/IMG_0754.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0758.jpg http://i254.photobucket.com/albums/h...C/IMG_0757.jpg More updates coming soon! |
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.... |
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/h...C/IMG_0772.jpg http://i254.photobucket.com/albums/h...C/IMG_0773.jpg Hole saw action: http://i254.photobucket.com/albums/h...C/IMG_0774.jpg http://i254.photobucket.com/albums/h...C/IMG_0775.jpg http://i254.photobucket.com/albums/h...C/IMG_0776.jpg http://i254.photobucket.com/albums/h...C/IMG_0777.jpg http://i254.photobucket.com/albums/h...C/IMG_0778.jpg And a -16 AN bung http://i254.photobucket.com/albums/h...C/IMG_0780.jpg |
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/h...C/IMG_0781.jpg http://i254.photobucket.com/albums/h...C/IMG_0782.jpg http://i254.photobucket.com/albums/h...C/IMG_0783.jpg http://i254.photobucket.com/albums/h...C/IMG_0784.jpg Installed: http://i254.photobucket.com/albums/h...C/IMG_0789.jpg http://i254.photobucket.com/albums/h...C/IMG_0788.jpg Everything still clears: http://i254.photobucket.com/albums/h...C/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/h...OCT-C-SL-1.gif What it is now: http://i254.photobucket.com/albums/h...C/IMG_0785.jpg http://i254.photobucket.com/albums/h...C/IMG_0786.jpg |
what made you decide to keep the AST?
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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/h...C/IMG_0802.jpg http://i254.photobucket.com/albums/h...C/IMG_0801.jpg This layout is going to look amazing: http://i254.photobucket.com/albums/h...C/IMG_0790.jpg http://i254.photobucket.com/albums/h...C/IMG_0791.jpg http://i254.photobucket.com/albums/h...C/IMG_0793.jpg Shortening the bends that couple to the intercooler: http://i254.photobucket.com/albums/h...C/IMG_0794.jpg http://i254.photobucket.com/albums/h...C/IMG_0795.jpg http://i254.photobucket.com/albums/h...C/IMG_0796.jpg You can see them poking up here: http://i254.photobucket.com/albums/h...C/IMG_0797.jpg http://i254.photobucket.com/albums/h...C/IMG_0798.jpg The supercharger outlet/FMIC inlet pipe will run right next to this one: http://i254.photobucket.com/albums/h...C/IMG_0799.jpg |
Had to trim the mount on the supercharger to clear the intake pipe:
http://i254.photobucket.com/albums/h...C/IMG_0803.jpg http://i254.photobucket.com/albums/h...C/IMG_0805.jpg Pretty close to what it will look like: http://i254.photobucket.com/albums/h...C/IMG_0800.jpg http://i254.photobucket.com/albums/h...C/IMG_0804.jpg http://i254.photobucket.com/albums/h...C/IMG_0804.jpg |
DIBS on first ride at DGRR!!!
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Damn, this thing is gonna be nasty. I love the fabrication alone. I really hope to be this skillful someday. Well done!
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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.
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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
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wire relocation has started:
http://i254.photobucket.com/albums/h...g/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/h...g/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/h...g/IMG_0825.jpg |
Awesome build!
Makes me wish I had a garage and a TIG :( |
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/h...n/IMG_0851.jpg http://i254.photobucket.com/albums/h...n/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/h...n/IMG_0849.jpg http://i254.photobucket.com/albums/h...n/IMG_0850.jpg Installed new level sensor on new oil pan. http://i254.photobucket.com/albums/h...n/IMG_0855.jpg http://i254.photobucket.com/albums/h...n/IMG_0856.jpg http://i254.photobucket.com/albums/h...n/IMG_0854.jpg Clean the block and also tap the holes to get any old sealant and dirt out: http://i254.photobucket.com/albums/h...n/IMG_0857.jpg Dimpled rear iron for a little extra adhesion: http://i254.photobucket.com/albums/h...n/IMG_0858.jpg All done (with powdercoated subframe and stainless hardware): http://i254.photobucket.com/albums/h...n/IMG_0862.jpg http://i254.photobucket.com/albums/h...n/IMG_0865.jpg http://i254.photobucket.com/albums/h...n/IMG_0864.jpg |
And here is my first attempt at a "how to" video. Be gentle, haha.
http://www.youtube.com/watch?v=lUGvK...ature=youtu.be |
Nice dude.... looks great. Any pics from the top for the rest? I'll see it tomorrow ;)
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how much was the oil pan, and level sensor... my wire broke too, and my pan might be a bit warped... lol
J. |
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.
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$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 |
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.
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Got ya, Thanks for the reply, that is what I thought.
John |
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/h...C/IMG_0885.jpg http://i254.photobucket.com/albums/h...C/IMG_0886.jpg A few welds on the back for strength: http://i254.photobucket.com/albums/h...C/IMG_0884.jpg The old V-band clamp that was trimmed for clearance: http://i254.photobucket.com/albums/h...C/IMG_0894.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0896.jpg http://i254.photobucket.com/albums/h...C/IMG_0897.jpg Now my new vband clamp can sit like this, and won't need a cutout: http://i254.photobucket.com/albums/h...C/IMG_0898.jpg modified compressor housing: http://i254.photobucket.com/albums/h...C/IMG_0888.jpg http://i254.photobucket.com/albums/h...C/IMG_0889.jpg Here you can see the powdercoated subframe: http://i254.photobucket.com/albums/h...C/IMG_0891.jpg |
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/h...C/IMG_0892.jpg http://i254.photobucket.com/albums/h...C/IMG_0893.jpg There won't really be any improvement in performance (maybe a little less heat soak), but it looks damn cool. |
SHOW THE VAC BLOCK!!!! Please?
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^ 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/h...C/IMG_0909.jpg http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0911.jpg http://i254.photobucket.com/albums/h...C/IMG_0910.jpg Fills through the old rear turbo drain: http://i254.photobucket.com/albums/h...C/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/h...C/IMG_0905.jpg http://i254.photobucket.com/albums/h...C/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. |
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/h...C/IMG_0912.jpg http://i254.photobucket.com/albums/h...C/IMG_0913.jpg http://i254.photobucket.com/albums/h...C/IMG_0914.jpg http://i254.photobucket.com/albums/h...C/IMG_0915.jpg http://i254.photobucket.com/albums/h...C/IMG_0916.jpg http://i254.photobucket.com/albums/h...C/IMG_0917.jpg |
Who makes that air pump delete idler wheel kit?
Thanks |
Tweakit Racing. A MUST for anyone who deleted thier air pump and likes thier bearings
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