Charlies7 Build up GT35R, Fuel, Everything -- goodies inside

charlies7 · 03-07-2009, 07:04 PM

Sup guys,

Figure now it is time that I finish the car that has been sitting in my garage for the past year and a half engine-less.

Here is a little background about the beast, or money pit. Bought the car in 2003 and the engine blew a coolant seal 100 miles later. I was still new to the rotary then and I wasn’t sure on what to look for when purchasing my first FD. Since then I have become very comfortable with the car and pretty much do all the work myself, that includes turbo manifold fabrication, intercooler setup's etc.

When the engine blew the first time I brought it to Banzai Racing in Indiana and all I have to say about them are good things. To this day I still order most of my necessities for the car that I can’t readily make. They have great customer service and the turn-around time is phenomenal. So I drove the car on that rebuild for 2 summers I was running around on a single turbo, T3 35R, which I didn’t really like and eventually went to a T4 divided 1.0 60-1 which I loved but lacked the response of the 35R that I once used.

Fast forward to Fall '07, I decided I wanted to do a N/A 20b swap. I had the funds together and had a majority of all the parts needed for the build. I just lacked one thing, the engine.

..

Well that dream died for now, and I went away to school and that’s pretty much where it ends until now. Now that I am almost done with my undergrad I have time to work on my own car and do some projects for a select few that are members on here. I am actually still finishing up a turbo kit for a forum member and keep making changes and designs that would make an awesome turbo kit..(Pictures to come). Luckily I am very fortunate for his patience and my constant design changes, but I know he wont be disappointed.

So these are the plans for the car and I hope to have it up and running come the end April.

I recently got a built engine from David and Kevin over at Rotary Rebuild Store. Haven’t heard a single bad thing and they have great customer service. David does the porting which, which looks great, and Kevin from Rotary Resurrection does the assembly. I had David and Kevin do the following to the engine:

Large SP
New rotor bearings
rebuilt oil pump
ALS 2mm seals (havent heard a bad thing about these)
Atkins thermal pellat

Then I decided to think about what turbo setup I wanted to run and I went with a GT35R 1.06 Divided. The housing is an TRUE twin scroll housing, not like some of the knock-off's that are out there with a T4 footprint only. Turbo kit will include the following:

-NEW GT35R turbo thanks to Glen over at AZRR
-Dual Tial 44mm wastegates with .9 bar springs
-Equal length fully divided manifold - ceramic coated
-3.5" 304L stainless manifold
-Custom CNC'd T4 flange, made by CJ Motorsports, designed by my cousin and I
-Hardlines for the cooling and oil drain

*Pictures to come

Cooling:

Intercooler being used is an old school Greddy trust 3 row. I haven’t decided if I am going to V-mount the setup or keep it as a front mount.

I am designing my own dual 19row oil cooler setup with a 180* thermostat, I figure this would be plenty for the fun track days this summer.

As far as the water pump setup, I plan on running a Meizere 55 GPM remote pump that is going to be controlled by a thermo-sensor and switch that kicks the pump on at 160 degrees F. I figure this is a great alternative to other aftermarket pumps and cleans up the engine A LOT. Also gives me ample room for my wastgates without the stock housings there

. I removed the ABS to mount a remote reservoir for the coolant where the ABS once was. The alternator will also be re-located to show off the incredible fuel system.

Fuel System:

I will be running the CJ Motorsports fuel system, by far one of the best setups on the market. I purchased (4) 1000cc and (2) 780cc Paul Yaw injectors from Glen over at AZRR. Again couldn’t be happier with the customer service.

The secondary rail will be machined for the famous Xcessive LIM and instead of using the typical Aeromotive FPR I decided to give Turbosmart a try with one of their -6 regulators.

I also have 4 Bosch 1680cc on the side incase I want to give E85 a go.

Exhaust:

The exhaust is going to be fabricated by me using 2 mufflers in series and be 3.5” stainless the whole way back. I haven’t decided what type of mufflers I plan on use but Borla XR-1 is on the top of the list.

Body:

Recently I picked up the entire black interior that I needed to complete the swap thanks to a local buddy/FD owner, also a forum member. Already have a genuine 99spec bumper that is waiting to be installed and its going off to paint, same color, vintage red. I removed the rear R1 spoiler (which is now for sale) and the rear wiper to get the holes filled for the clean shaven look.

Here is the remainder of the list of parts I have going on:

GZ Xcessive LIM
Crane Cams HI-6 ignition amplifier
Garfinkle engine torque brace
Cusco strut tower bar
JDM UIM

I’m sure there are more I just can’t think of anything of the top of my head at the moment.

Pretty much these are the plans for the car. It won’t be the original build that most see so I hope that it stands out and gives others ideas.

I will be sure to add some pictures as I get them coming in and have time to work on the car. The engine should be going in next week and once the engine is in its game time.

If anyone has any questions or suggestions please feel free to chime in

-Charlie

lt1_fd3s · 03-07-2009, 07:14 PM

and...

charlies7 · 03-07-2009, 07:14 PM

EJayCe996 · 03-07-2009, 07:20 PM

too clean...I'd hate getting it dirty

***TitaniumTT*** · 03-07-2009, 09:58 PM

Damn nice porting David

Brent · 03-10-2009, 01:09 PM

bout damn time Charlie!

Glad to see you'll get some use out of it this summer.

Batmobile · 03-10-2009, 01:12 PM

You forgot to put the E-shaft in.

vex · 03-10-2009, 01:14 PM

Sooooo shiney

charlies7 · 03-20-2009, 12:34 AM

35R kit is going to be for sale here shortly when its done. S372 here I come

AzEKnightz · 03-20-2009, 01:08 AM

haha, so this is the "secret" huh charlie!! I cant wait for the final product. Neither can I for my final product =)

-Eric

Proxy One · 03-20-2009, 11:47 AM

I may just be interested in the 35R kit. Ive been playing with the idea of getting one. Is it a A-Spec or Rx7store or what?

charlies7 · 03-20-2009, 01:49 PM

Your first priority

Quote:

Originally Posted by AzEKnightz

haha, so this is the "secret" huh charlie!! I cant wait for the final product. Neither can I for my final product =)

-Eric

charlies7 · 03-20-2009, 01:50 PM

It's MINE!

PM if you like.

Quote:

Originally Posted by Proxy One

I may just be interested in the 35R kit. Ive been playing with the idea of getting one. Is it a A-Spec or Rx7store or what?

Proxy One · 03-20-2009, 02:26 PM

Which kit is it?

AzEKnightz · 03-20-2009, 02:48 PM

Charlie is a good guy. I am sure alot of guys can vouch for him. I think he meant **he customize the Kit itself. So it does not belong to A-Spec nor RX7Store. Hope this cleared things up.

-Eric

03-07-2009, 07:04 PM	#1
charlies7 one broke moderator Join Date: Feb 2008 Location: Chicago Posts: 319 Rep Power: 18	Charlies7 Build up GT35R, Fuel, Everything -- goodies inside Sup guys, Figure now it is time that I finish the car that has been sitting in my garage for the past year and a half engine-less. Here is a little background about the beast, or money pit. Bought the car in 2003 and the engine blew a coolant seal 100 miles later. I was still new to the rotary then and I wasn’t sure on what to look for when purchasing my first FD. Since then I have become very comfortable with the car and pretty much do all the work myself, that includes turbo manifold fabrication, intercooler setup's etc. When the engine blew the first time I brought it to Banzai Racing in Indiana and all I have to say about them are good things. To this day I still order most of my necessities for the car that I can’t readily make. They have great customer service and the turn-around time is phenomenal. So I drove the car on that rebuild for 2 summers I was running around on a single turbo, T3 35R, which I didn’t really like and eventually went to a T4 divided 1.0 60-1 which I loved but lacked the response of the 35R that I once used. Fast forward to Fall '07, I decided I wanted to do a N/A 20b swap. I had the funds together and had a majority of all the parts needed for the build. I just lacked one thing, the engine. .. Well that dream died for now, and I went away to school and that’s pretty much where it ends until now. Now that I am almost done with my undergrad I have time to work on my own car and do some projects for a select few that are members on here. I am actually still finishing up a turbo kit for a forum member and keep making changes and designs that would make an awesome turbo kit..(Pictures to come). Luckily I am very fortunate for his patience and my constant design changes, but I know he wont be disappointed. So these are the plans for the car and I hope to have it up and running come the end April. I recently got a built engine from David and Kevin over at Rotary Rebuild Store. Haven’t heard a single bad thing and they have great customer service. David does the porting which, which looks great, and Kevin from Rotary Resurrection does the assembly. I had David and Kevin do the following to the engine: Large SP New rotor bearings rebuilt oil pump ALS 2mm seals (havent heard a bad thing about these) Atkins thermal pellat Then I decided to think about what turbo setup I wanted to run and I went with a GT35R 1.06 Divided. The housing is an TRUE twin scroll housing, not like some of the knock-off's that are out there with a T4 footprint only. Turbo kit will include the following: -NEW GT35R turbo thanks to Glen over at AZRR -Dual Tial 44mm wastegates with .9 bar springs -Equal length fully divided manifold - ceramic coated -3.5" 304L stainless manifold -Custom CNC'd T4 flange, made by CJ Motorsports, designed by my cousin and I -Hardlines for the cooling and oil drain Pictures to come Cooling:* Intercooler being used is an old school Greddy trust 3 row. I haven’t decided if I am going to V-mount the setup or keep it as a front mount. I am designing my own dual 19row oil cooler setup with a 180* thermostat, I figure this would be plenty for the fun track days this summer. As far as the water pump setup, I plan on running a Meizere 55 GPM remote pump that is going to be controlled by a thermo-sensor and switch that kicks the pump on at 160 degrees F. I figure this is a great alternative to other aftermarket pumps and cleans up the engine A LOT. Also gives me ample room for my wastgates without the stock housings there . I removed the ABS to mount a remote reservoir for the coolant where the ABS once was. The alternator will also be re-located to show off the incredible fuel system. Fuel System: I will be running the CJ Motorsports fuel system, by far one of the best setups on the market. I purchased (4) 1000cc and (2) 780cc Paul Yaw injectors from Glen over at AZRR. Again couldn’t be happier with the customer service. The secondary rail will be machined for the famous Xcessive LIM and instead of using the typical Aeromotive FPR I decided to give Turbosmart a try with one of their -6 regulators. I also have 4 Bosch 1680cc on the side incase I want to give E85 a go. Exhaust: The exhaust is going to be fabricated by me using 2 mufflers in series and be 3.5” stainless the whole way back. I haven’t decided what type of mufflers I plan on use but Borla XR-1 is on the top of the list. Body: Recently I picked up the entire black interior that I needed to complete the swap thanks to a local buddy/FD owner, also a forum member. Already have a genuine 99spec bumper that is waiting to be installed and its going off to paint, same color, vintage red. I removed the rear R1 spoiler (which is now for sale) and the rear wiper to get the holes filled for the clean shaven look. Here is the remainder of the list of parts I have going on: GZ Xcessive LIM Crane Cams HI-6 ignition amplifier Garfinkle engine torque brace Cusco strut tower bar JDM UIM I’m sure there are more I just can’t think of anything of the top of my head at the moment. Pretty much these are the plans for the car. It won’t be the original build that most see so I hope that it stands out and gives others ideas. I will be sure to add some pictures as I get them coming in and have time to work on the car. The engine should be going in next week and once the engine is in its game time. If anyone has any questions or suggestions please feel free to chime in -Charlie

03-07-2009, 07:14 PM	#2
lt1_fd3s WNC Tour Guide Join Date: Feb 2008 Location: WNC Posts: 780 Rep Power: 18	and... __________________ WNC Tour Guide - Including the Tail of the Dragon - PM for details Last edited by lt1_fd3s; 03-07-2009 at 07:20 PM.

03-07-2009, 07:14 PM	#3
charlies7 one broke moderator Join Date: Feb 2008 Location: Chicago Posts: 319 Rep Power: 18	Engine Pics from David

03-07-2009, 07:20 PM	#4
EJayCe996 PPP-P-P-P-POWER! Join Date: Feb 2008 Location: North GP, TX Posts: 283 Rep Power: 18	too clean...I'd hate getting it dirty __________________ 1. Walk through a row of 22", or larger, rims 2. Say you love dubstep 3. ????? 4. PROFIT! Axiomatic: Total cacology.

03-10-2009, 01:09 PM	#6
Brent Sua Sponte Join Date: Feb 2008 Location: Killeen, TX Posts: 839 Rep Power: 18	bout damn time Charlie! Glad to see you'll get some use out of it this summer. __________________ Road Atlanta August 2011 NASA TT 1:33 http://www.youtube.com/watch?v=IFY00PAK_Ps Traqmate's video of my car from the 2011 UTCC at VIR http://www.youtube.com/watch?v=2Zcn6...layer_embedded Video of Yellow LS1 FD at NASA TT at VIR http://www.youtube.com/watch?v=e6k0lJkcwrM

03-07-2009, 09:58 PM	#5
*TitaniumTT* Test Whore - Admin Join Date: Mar 2008 Location: Right Behind you son Posts: 4,581 Rep Power: 10	Damn nice porting David

03-10-2009, 01:12 PM	#7
Batmobile The Newbie Join Date: Mar 2008 Posts: 22 Rep Power: 0	You forgot to put the E-shaft in.

03-10-2009, 01:14 PM	#8
vex RCC Loves Me Not You Join Date: Jul 2008 Location: Influx. Posts: 2,113 Rep Power: 19	Sooooo shiney __________________ The Official FC Radiator Thread My Project Thread: Cerberus CCVT Virginia Rotary Group

03-20-2009, 12:34 AM	#9
charlies7 one broke moderator Join Date: Feb 2008 Location: Chicago Posts: 319 Rep Power: 18	35R kit is going to be for sale here shortly when its done. S372 here I come

03-20-2009, 01:08 AM	#10
AzEKnightz ZooM ZooM!! Join Date: Jun 2008 Location: SF, CA Posts: 90 Rep Power: 17	haha, so this is the "secret" huh charlie!! I cant wait for the final product. Neither can I for my final product =) -Eric

03-20-2009, 11:47 AM	#11
Proxy One Victory Is Mine Join Date: Feb 2008 Location: Suwanee GA Posts: 428 Rep Power: 18	I may just be interested in the 35R kit. Ive been playing with the idea of getting one. Is it a A-Spec or Rx7store or what? __________________ www.dealsgaprotaryrally.com 1994 Rx7 White 2001 RZ GT35R'd 1972 Rx2 Orange Coupe 5spd 2006 STi 1986 Buick GN

03-20-2009, 02:26 PM	#14
Proxy One Victory Is Mine Join Date: Feb 2008 Location: Suwanee GA Posts: 428 Rep Power: 18	Which kit is it? __________________ www.dealsgaprotaryrally.com 1994 Rx7 White 2001 RZ GT35R'd 1972 Rx2 Orange Coupe 5spd 2006 STi 1986 Buick GN

03-20-2009, 02:48 PM	#15
AzEKnightz ZooM ZooM!! Join Date: Jun 2008 Location: SF, CA Posts: 90 Rep Power: 17	Charlie is a good guy. I am sure alot of guys can vouch for him. I think he meant **he customize the Kit itself. So it does not belong to A-Spec nor RX7Store. Hope this cleared things up. -Eric

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