My latest build. S475 etc
 

i was going to wait until the car was up and running before posting anything, but i just couldnt resist. things are coming along nicely, so here we go.

a little history:

i first bought the car almost 3 years ago and it has been through a good bit. it started out almost bone stock with a pretty low mile re-man in it. i drove it with a full turbo-back, intake, pfc, and tune for roughly ~20kmiles as my dd. then got power hungry and leaving the engine stock built a 35r kit around it and bumped the power up to 440whp on pump and meth at 18-19psi.

then to make a long story short back when we had the "gas crisis" i ended up with 87 in the tank and cracked an apex seal. i was mad for about 10 minutes then realized that gave me an excuse to build it even more.

so come to present day and i have all of my parts either ordered or waiting install and i plan to come to DGRR with it atleast running and being broken in.

The Build

engine:

-large streetport with new rotor housings by David Jerome@ rotaryrebuildstore
-balenced(10k) and clearanced rotating assembly by Roger Mandevile
-Guru oversized stud kit
-ALS apex seals
-built by myself

turbo setup:

-Bullseye/Borg Warner S475R (T6 1.32 a/r exhaust, the big boy!!)
-custom exhaust manifold and 4 inch DP by Charlie Ruetsche(charlies7 on here)
-twin tial 44mm wastegates
-all ceramic coated

fuel, intake, ecu

-made the jump from pfc to a Haltech e8
-CJ motorsports fuel system
-850 primary, 4 1680 secondary
-GZ/Xcessive LIM
-twin supra pumps
-twin -6 feed lines
-12x24x4 fmic. mounts and piping fabbed by myself
-water injection
-Q16

exhaust:

-full 4 inch fabbed by myself.
-borla xr-1 muffler
-screamer pipes on wastegates

ignition:

-4 msd blaster coils
-1 msd dis2 box
-2 msd digital 6 boxes

chassis/transmission

-Exedy twin disc
-aspec trans brace
-kg parts diff brace
-solid engine mounts
-garfinkle engine torque brace
-short shifter
-spare tranny for when i destroy the first one!!
-at some point it will get a rebuilt S4 Tii diff aswell and chromoly axels

also while the car is down i did/am doing some exterior mods aswell which consist of

-full '99 spec front end
-shine auto undertray
-shine auto rear diffuser
-shine auto tailight spoiler


i think that about cover the build, but im sure there are somethings i forgot. if i forgot to mention someone's name im sorry. lol now onto the progress

this past weekend i got my rotor housings and irons back from a-spec from machining for the stud kit. i then painte and assembled the engine, bolted the tranny up, and dropped it in. my manifold and DP are supposed to be finished at the end of this week so i should have some more updates for you guys soon.

pics!!


http://rotarycarclub.com/rotary_foru...1&d=1236612316
http://rotarycarclub.com/rotary_foru...1&d=1236616428
http://rotarycarclub.com/rotary_foru...1&d=1236616428
http://rotarycarclub.com/rotary_foru...1&d=1236612664
http://rotarycarclub.com/rotary_foru...1&d=1236616428

one more pic

http://rotarycarclub.com/rotary_foru...1&d=1236612795

3 yrs?!?!? no...more like 2 yrs at most... You picked it up after I wrecked my red car and that was in early '07. =]

sorry i didn't make down to help out, I ended up trying to figure out some issues with another FD. Only after I got home and was thinking about it, I'm thinking the wastegate on it isn't even opening, the PowerFC is acting up and it isn't tuned.

I say the PFC is acting up because it was reading water temp of 40-45, I swapped it out to a different PFC and that one was reading water temp of 65.

ok, i don't mean to thread jack...

heh, that thing is too big. Just holding that thing for mock up almost broke my back. Thank god I had 2 sets of extra hands :).

Anyways I would have recommended going with an electric water pump setup. Cleans up the engine bay alot more and is way more effective that the 15 year old pump.

Also sent you an email

-Charlie

No one cares about your problems :).. :beatdeadhorse5:

good to see you finally got a clutch. since last year at DGRR it was slipping like crazy

what are you talking about?

What does the R signify?

Race compressor cover.

correct.

i have something for you charlie.

looking nice... ERNIE T killer!!!! Just adding a little pressure! Ernie has a deal with Ray were no cars he tunes can make more than him (LOL).... So I am guessing you at 739rwhp...... Gonna have it at the gap?

Looks hot buddy!!

Can't wait to see this manifold and margarita mixer.

Hey, did the monkey help you on assembly very much? or is he all thumbs?? :lol:

yep, it will be there. and i already have ray payed off so it will make more! 800!!!! lol. maybe once then dial it back. we shall see what boost level we are at etc.

joe, monkey didnt do jack shit except for make my beer disapear??? i heard you might come hang out with us for a few days after DGRR?

I think I just fell back in love w/ my Nikon after seeing those pictures! So uh... you can definitely sand something w/ all that GRAIN! Looking good tho man. Guys it is sooo much cleaner in person. Don't be fooled by the terrible pictures.

Yeah I might be tagging along when you guys head back, check out some of your stomping grounds before heading to the keys! We'll see you at the gap though and take it from there.

Good luck with the project, won't be long now!

if you had gotten your ass out of bed, then we could have taken them with your camera, but how late did you sleep? was it 4 or 6pm?

i was part of the caravan from spartanburg last year. i rode with kerrigan. you told me that your car was rich cause when you were getting it tuned your clutch was slipping. so it was on a really rich tune.

it was slipping on the dyno since my dumbass didnt adjust the pedal when i put the then new clutch in. on the way to DGRR, i wasnt slipping. lol

Can't wait to see your car this year. Loved it last year already, good luck with it.

well i got a few things done this weekend. got the FMIC mounted up and the bumper trimmed up for it so i can have it painted this week. also did 95% of the haltech harness today(thanks reese!) all thats left are the trigger wires which i will do tomorrow. onto some pics! i will have a pic of the finished haltech harness tomorrow.

http://i698.photobucket.com/albums/v...d/DSC04487.jpg
http://i698.photobucket.com/albums/v...d/DSC04494.jpg
http://i698.photobucket.com/albums/v...d/DSC04495.jpg
http://i698.photobucket.com/albums/v...d/DSC04488.jpg

and allen(rotarybeat1287) was actually working on his car for a change!!


http://i698.photobucket.com/albums/v...d/DSC04492.jpg
http://i698.photobucket.com/albums/v...d/DSC04493.jpg
http://i698.photobucket.com/albums/v...d/DSC04490.jpg

Allen worked on his car on Sunday...

For those who are interested in the turbo placement... :driving:

Manifold is made out of heavy wall .120 wall thickness. The turbo fits snuggly between the frame and the waterpump housing with approximately .150-.200" around.

http://i246.photobucket.com/albums/g...s/DSCF0275.jpg

http://i246.photobucket.com/albums/g...s/DSCF0277.jpg

http://i246.photobucket.com/albums/g...s/DSCF0278.jpg

Hot damn!

2" primaries?

Yes.

Wastegates are being placed tonight and a little modifications to the waterpump housing is needed ;).

Thats a monster under the hood!

This thing is HUGE. Makes me want to change my setup just to be a baller like Masin.

Yeah, I here ya.. Been thinking 4202 myself..

I plan on selling my 35r setup for a S372..101.9mm :)

That unit is also big! I was holding one the other day and it looks like the size of a 42r

damn charlie, that shit is sick. cant wait to hold it!!

"On a rotary, its not a turbo if it ain't the same size or bigger than the motor."
:)

hell yes!

a small update. the downpipe and wastegate tubes are tacked up. getting fully tigged today and shipped back tomorrow!! here are a few cell phone pics from charlie.

http://i698.photobucket.com/albums/v...wastegates.jpg
http://i698.photobucket.com/albums/v...d/NewImage.jpg

Wow, my cell phone camera did a good job suprisingly.

better get some heat shielding on that LIM!

^You know like 500degree intake temps? :lol:

Everything related to the exhaust is going to be ceramic coated. I know it looks like the DP is right on the LIM but it really isnt as bad as it looks. Idea was to keep the transition from the 5" to 4" as long as possible. The LIM is also ceramic coated as a thermal barrier.

However, I bet this kit will out perform many other out there. ;) Boost creep should be non-exsistant and the T6 flange has a very nice transition for flow, thanks to the help from a CNC.:icon_tup: To bad no one can see the machine work, maybe thats a good thing. :rofl:

Good craftsmanship Charlie! There's no holes between the tubing so that shows precise and thought-out planning. Should be a killer setup :)

the dp is also going to have header wrap on it and i may even put some of that DEI thermal barrier on the LIM to further protect it. we shall see.

well boys a small peek at a an upcoming update. i got everything back from charlie today and it is beautiful!! here are some pics of the dp. i took it all to get ceramic coated this morning and will have it all back tomorrow afternoon or sunday morning. then it will be all put on the car and a ton of pics taken. here it is!

http://i698.photobucket.com/albums/v...d/DSC04496.jpg

check out these welds

http://i698.photobucket.com/albums/v...d/DSC04498.jpg