1996 EK Hatch - High HP Kseries Drag Build (IT RUNS! Vid page 19) [Archive] - TriStateTuners.com

SovXietday

12-18-2011, 06:15 PM

Troll suggested I make a dedicated thread for the hatch, so here it is.

For reference back to what I've already accomplished with this car, and a good portion of the story to how it got to this point, please reference my main thread here.

Sov's Cars and Projects (http://www.tristatetuners.com/forum/showthread.php?t=61597)

Goal - 700-800whp, 9 second 1/4 mile.

Me and going dual cam is long overdue, it's going to be really weird surpassing what took me 4 years with a Dseries with just pump gas and low boost on this build.

I'm starting with a block that came straight out of a 2007 Honda Civic Si (K20Z3). There is some form of damage on cylinder 4. I have yet to open the block up because I'm waiting for my engine stand to come in (Christmas present/on backorder). Once I do I'll be able to assess the damage, but the plan is for rods/pistons anyway so at worst it will be a simple small overbore and that'll be that.

Order of Operations (Order in which I lose all my money.:-p)

Step 1: Build Block

http://i305.photobucket.com/albums/nn212/SovXietday/block1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block3.jpg

Need to tear it down, at least get the rods and pistons out. I need to get chain guides, tensioner, timing chain, crank pulley, timing covers, and water pump. This will just be the stock stuff (except for tensioner), I learned a long time ago that Honda builds engines quite well mechanically. (These engines bone stock will do over 600).

-STOCK SLEEVES <-- read that carefully, and yes they will hold just fine.

-Wiseco pistons (~10:1)
-Eagle Rods
-New OEM Rod Bearings (again, no need to get ACL/Clevite/etc)

Step 2: Build Head - CHECK

-K20A2 head
-Clean up port job
-Stock A2 cams for now
-Supertech dual valve springs
-Supertech Ti retainers
-Stock Valves
-ARP Head Studs

Step 3: Transmission

For now, the transmission will be pretty simple. I will then upgrade things as I can.

-Base RSX 5 speed
-CC Twin disc
-Mfactory LSD
-Whatever axles I can make fit for now (I like having weak axles, they break and are cheap to replace, vs transmission stuff which is not).
-Scatter Shield (the thick metal plate that helps to contain and exploded, expensive, twin disc if that were to ever occur).

Step 4: Complete the full swap

-Wiring Harness
-Shift box/cables
-Innovative Solid Billet Mounts ;)
-K-PRO ECU

I'm not about to spend like $350 on a wiring conversion harness. I will do all of that myself. Car will likely also receive a brake line tuck (gives me more room) and full cleanup and spray of the bay. Not sure I care to shave it though, we'll see.

Step 5: Fabricate Entire Turbo Setup

-Make sidewinder divided manifold, dual wastegate.
-Precision 6766 Billet Journal Bearing Turbo - T4 divided 1.00AR/Vband 3 5/8" out
-4" exhaust.
-Twin Tial 38mm MVS, dual 1.75" dumps with exhaust.
-Building intake manifold.
-1000hp A2A core, mount and fabricate endtanks
-3" IC piping
-TiAL BOV

Step 6: Fuel System

Dual Bosch 044 (Possibly Weldon pump)
2000CC injectors
8AN feed/6AN return
Normal FPR/Fuel Rail setup.

Not really sure if I'm going to build my own fuel cell and go with a sump setup, or just work from the stock tank yet. Also don't know if I'm going to stay E85 or switch back over to gas and C16. Depends on when I max those injectors, I refuse to buy $1000 ID2000s.

Step 7: Finish odds-ends/Tune/Track

Finish up whatever I need to in the setup.
Tune the car (will likely travel up to see Derek at Innovative Motorsports who has always offered help in my ridiculous endeavors).
Take it to the track and break ****. Fix. Continue to run slow times. Learn something. Run faster. Break more. Fix. Rinse repeat until I finally get kicked out lol.

Eventual Plans

-To go 9s, I will need to add to my current 6pt. I won't be doing this until I go too fast. Once I do, I will be doing the rest of the cage myself. May also need a chute? I will have to look more into this when the time comes.

-Front end change. I will probably be going with the common three piece front ends that you see on a lot of drag cars. This will allow me to tuck my slicks behind the fenders and be a lot more aerodynamic, which is nice. Till then, car will just have to look like crap.

-Suspension overhaul. The Koni/Grounds were great for street driving, but it will likely be changing to a drag setup. This is fairly low on the list.

-PPG Gearset... yeah kinda just dreaming on that one.

-Cutting out more weight (doors, lexan, etc) and probably creating a diffuser under the rear bumper.

Love how it sounds so easy saying it. Oh well, I'll figure it out. To be continued! (obviously).

jen.

12-18-2011, 06:22 PM

SO EXCITED! You've got a motor coming from the best car/year. But I'm clearly very biased so my opinion doesn't really count. But still, so excited!

sleeper15

12-18-2011, 06:46 PM

where's the like button?

sleeperSL2

12-18-2011, 08:24 PM

In for awesomeness

Proven

12-18-2011, 09:00 PM

ricky2i5

12-19-2011, 12:35 AM

I dig Kseries hatches

In for this build

JST2KWIK

12-19-2011, 01:14 AM

WOW this is going to be sick! Can't wait to see some progress

jen.

12-19-2011, 11:00 AM

T
Step 3: Transmission

For now, the transmission will be pretty simple. I will then upgrade things as I can.

-K20A3 5 speed
-CC Twin disc
-Mfactory LSD?
-Whatever axles I can make fit for now (I like having weak axles, they break and are cheap to replace, vs transmission stuff which is not).
-Scatter Shield (the thick metal plate that helps to contain and exploded, expensive, twin disc if that were to ever occur).

Aaron, I forgot to mention, this is the best idea ever. I mean, I know you already know, but the K series 6 speed trannys are no beuno. Can't wait to see how this works out for you.

Asif22

12-19-2011, 03:35 PM

Amazing. I really liked your single cam build. For the trans look into jotech. He rain 11.3 stock motor then 11.0 with a z3 trans. He said it was shimmed and cryotreated.
http://www.youtube.com/watch?v=stS-7HAMSFY

SovXietday

12-19-2011, 06:31 PM

Sick stuff, Glad you started a new build thread for the K-series.

Thing I'm most interested in is your building your own Intake manifold? Would love to see a left side feed, or better yet a bottom/center feed like so - http://www.haywardperformance.com/ ...You should be able to salvage your current fmic and avoid harsh bends in piping..

What about oil pump? The modified S2K from ERL?

As for the injectors, You should write up a proposal to ID (or any vendors selling it) for sponsorship, even partial. A simple collection of vid's, pics, time slips, and link's to your build thread/s showing them your sh*t's getting sweated might do the trick. Hell, you should be doing it for all parts! DEI sent me free stuff from my proposal just for being featured in SCC in 04, Kartboy too, and Titan sent me headers 50% off (granted I emailed like 150 companies) it does work.

Plan on building a center feed IM, so I can go backdoor off the IC. I need to change out my IC though, I don't think my core can support my goals. At least, I should say that I don't know, and therefore don't trust it.

As for the oil pump, just going to use the Z3. Clean it up and port the the output hole so that it's less prone to cavitation and I have full faith in it. Considering I'm spinning a weaksauce Dseries pump to the moon as is, I don't think I'll have an issue with this one.

Amazing. I really liked your single cam build. For the trans look into jotech. He rain 11.3 stock motor then 11.0 with a z3 trans. He said it was shimmed and cryotreated.
http://www.youtube.com/watch?v=stS-7HAMSFY

Thanks man! I'm still looking into trans options, but I remember seeing someone who had some interesting treatments that had made quite a difference in gear strength. We'll see what I can find when I get there.

Thanks everyone! Can't wait to get started!

saxon

12-19-2011, 07:27 PM

speedooo

12-20-2011, 12:28 PM

SovXietday

12-20-2011, 09:48 PM

with that much power you will have a hard time finding a transmission that will hold it unless you go with a dog box

anything over 500whp and its a coinflip if it will last that pass or not

shaun at IMW in Carlisle is really well versed with those transmissions and he is the one i had check over my K trans and install the quaife

looks like a nice build and power shouldnt be a problem, only thing i dont understand is why your going with a 2.0 instead of the 2.4

Ideally I would love to go with a PPG dogbox, but I could go through 10 stock transmissions at that price. I can afford to break a stock trans with an LSD, I can't afford to break a PPG box. I am well versed in transmissions, my Dseries has a one of a kind transmission with LSD that I put together, so I'll address the issue when I start breaking stuff.

As for the 2.0, a few reasons really.
-I'd have to sleeve a 2.4, the walls are too thin to support the power.
-2.4 limits how high I can rev the engine. This means I will have a smaller powerband and a probably not enough RPM to get the MPH out of 4th gear.
-2.0 block is free, 2.4L is not lol.

justinlansdale

12-20-2011, 09:51 PM

I'm thinking that you should let me photo-document your entire build for you!

civictype_r

12-20-2011, 09:56 PM

Can't wait till you get this build going dude!!!

SovXietday

12-20-2011, 09:57 PM

I'm thinking that you absolutely should, haha.

Asif22

12-21-2011, 12:36 AM

I'd rather have the 2.0 too. I wish I had a 2.0 in my ap2 instead of the 2.2. I just love to rev and the F22 has too much stroke

boostedfury

12-21-2011, 12:51 AM

in for all the madness!

tigasTT

12-21-2011, 01:17 AM

Subd..

jesse096

12-21-2011, 02:19 AM

So in for this!

-Jesse

CHR!S

12-21-2011, 11:35 AM

aaron :thumbup:

ketchup!

12-22-2011, 04:38 PM

any idea on goal et time?

SovXietday

12-23-2011, 07:22 PM

Going for 9s.

So yesterday it was actually pretty nice out, so I pulled off as much as I could from the car. All I have to do now is drop the engine, but I can't do it in in the trailer.

http://i305.photobucket.com/albums/nn212/SovXietday/dseries1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/dseries3.jpg
Not going to lie, feels really weird to tear apart something you've spent a good 5 years on building. But bigger and better things are on the way, just not used to having huge amounts of downtime with it lol.

http://i305.photobucket.com/albums/nn212/SovXietday/dseries2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/dseries4.jpg
Exhaust and all IC piping off. Took like 15 minutes lol!

http://i305.photobucket.com/albums/nn212/SovXietday/dseries5.jpg
I wasn't always very good at welding. :/

http://i305.photobucket.com/albums/nn212/SovXietday/dseries6.jpg
Going to miss this turbo, whoever ends up taking it off my hands will be a happy camper.

http://i305.photobucket.com/albums/nn212/SovXietday/dseries7.jpg
All done. Going to drop the rest of what I have probably next weekend and put it up for sale.

Even better news is, my engine stand gets here tomorrow. So engine should be mounted so I can tear it down. I took a look at the cylinder that was damaged and there looks to be no damage to the walls, so probably just a burned up ring. This is good news, because if it's true then I won't need any kind of machining at all and I can order pistons and rods and get moving!

Till then, Happy Holidays everyone!

SovXietday

12-28-2011, 09:32 PM

Update!

First of all, I purchase a K20A2 head that will be shipped out after the New Year.
-Supertech dual valve springs
-Supertech Ti retainers
-Stock Valves
-Mild "cleanup" port job
-Type S cams

Got it for a pretty good price too, plus I hate doing headwork lol.

Engine stand finally came in today, so I mounted the block and did the tear down. Compression test showed no compression in cylinder 4, so I was eager to see what the issue was.

http://i305.photobucket.com/albums/nn212/SovXietday/block4.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block6.jpg
Now THAT is an oil pump, holy damn lol.

http://i305.photobucket.com/albums/nn212/SovXietday/block7.jpg
Bag and tag son. I'm terrible with remembering what bolts go where.

http://i305.photobucket.com/albums/nn212/SovXietday/block8.jpg
Stock pistons out.

http://i305.photobucket.com/albums/nn212/SovXietday/block9.jpg
Rod journals and bearings all look brand friggen new. Absolutely nothing wrong with them at all.

http://i305.photobucket.com/albums/nn212/SovXietday/block10.jpg
Remember no compression in cylinder 4? Well... no ringlands would do that pretty well lol.

http://i305.photobucket.com/albums/nn212/SovXietday/block11.jpg
Ouch, poor oil ring.

http://i305.photobucket.com/albums/nn212/SovXietday/block12.jpg
Here's number 1 piston. See the small little piece of metal? That's a cracked ring. 4 melted down, but 1 was wasn't far behind.

Prognosis - The car was turbocharged, broken, and then returned to stock for the warranty work. Intake side of all 4 pistons, especially bad on number 1 and 4, show signs of way too much heat. Detonation likely, but looks to me like they ran it lean and the heat created the ringland failure. I looked into the cylinder expecting heavy scarring on the sleeve, but there wasn't any at all. Don't know how, but all four cylinder walls are damn near perfect.

So. Plan is pretty simple. Eagle rods, 87mm Wiseco or CP pistons (10.0:1 compression) depending on what I can find, and put some new bearings in. I'm not even going to bother taking the girdle off, the rod journals are perfect and they get less oil than the mains do. Heck, I can still see the bearing COLOR code on all of the bearings on the rods. Pretty cool, I've never gotten to mess with an engine that is this fresh before. Much less work to do lol.

Going to try and get the block built soon. Drop the head on and stare at in in awe for like 2 years while I save up for everything else LOL.

The first fab on this build will be for the remote 12V water pump. ;)

DPancoast

12-28-2011, 09:51 PM

I love threads like this

civictype_r

12-29-2011, 07:33 PM

Poor piston rings!

Sent from my HTC THUNDERBOLT 4G LTE using tapatalk

SovXietday

01-06-2012, 12:14 AM

Yay update.

Head comes in tomorrow. Crank pulley and VC will be here soon as well. Can't remember if I have anything else random stuff ordered at the moment, don't think so. Need the crank pulley to continue on the project that I started today, so hopefully this weekend I can get going on that.

More exciting news is that I ordered everything to finish the block! (well, except for rod bearings).

-86mm Wiseco 9.8:1
-Eagle Rods
-ARP Head Studs

Not boring out the block. It's got 7K miles, the sleeves are in good shape, and I want alllll the sleeve material possible lol. Quick hone, check my P2W, check my ring gap, size up my bearings and get the block together real quicklike. I still need a bunch of little stupid **** though, so it's been a bit of a pain sourcing that.

Other than that, got a little bit of work in. I wanted to open up the oil pump and port out the 90 degree turn from the pickup into the pump. At least, that's what I've been led to believe is there.

http://i305.photobucket.com/albums/nn212/SovXietday/block13.jpg
Again, biggest oil pump ever, damn!

http://i305.photobucket.com/albums/nn212/SovXietday/block14.jpg
Cover off, the pump is driven through two balancing shafts instead of directly. Pretty neat. I also determined by measuring the gears that the pump spins at half engine RPM. So if the pump begins to cavatate at 5K rpms that means that I can rev the engine to 10K safely. I should be able to rev this to 9K no problem, I wasn't really planning on revving much higher so that's fine.

http://i305.photobucket.com/albums/nn212/SovXietday/block15.jpg
Here is the pressure release spring and seat

http://i305.photobucket.com/albums/nn212/SovXietday/block16.jpg
Took a small lock washer, flattened it, and used it to shim the spring. Should allow for the pump to put out more oil pressure before it begins to relieve pressure, the higher pressure should also give me more RPMs before the pump begins having issues. I don't want to shim it a whole lot, the last thing I want is for the spring to bind and not relieve pressure if it has to.

http://i305.photobucket.com/albums/nn212/SovXietday/block17.jpg
Here's the intake port, I cleaned it up and shallowed it out just a little bit but overall it's not really going to make any difference. From here I just reassembled it and now it's ready to go.

Then it was onto the next little bit. I am not going to run the stock water pump on this build, but instead I'm going to run an electric pump. There are several reasons for this.
1) Sourcing that huge water pump/PCV housing is a real PITA
2) It's extremely expensive. Not only do I have to get all of that stuff, but I have to get an idler pulley and AC/PS delete kit. F that. This will actually be cheaper, lol.
3) Can't argue with free power, and since the car won't be on the road I don't need to worry about the water pump not working well on the street.

So, first things first, pull the stray stud out of the block. Easy right? Pliers... yeah didn't work. So I got a little intuitive.

http://i305.photobucket.com/albums/nn212/SovXietday/block18.jpg
Ground down the stud flat on two sides, and then started trying to twist it out. Hooooooollyyy hell, I was damn near standing on it (not that I weigh much, lol), **** was barely moving.

http://i305.photobucket.com/albums/nn212/SovXietday/block19.jpg
"Godammnitmother****ingsonofabitch****youpieceofgod damit****inghatethis****"

http://i305.photobucket.com/albums/nn212/SovXietday/block20.jpg
Drilled it out, then cleaned it up and drilled it slightly bigger, and tapped it with a 7/16 20 thread. I put that here so I can remember later, lol, I don't have metric drill bits. :(

http://i305.photobucket.com/albums/nn212/SovXietday/block21.jpg
Remember art class? Well I'll be damned, it came in handy. Now all I have to do is transpose this to a sheet of aluminum and cut it out.

http://i305.photobucket.com/albums/nn212/SovXietday/block22.jpg
Hey, transposed. This is 1/4" thick aluminum, so no, I'm not cutting out the little intricacies. Funny thing is, the little kit you can buy for $250 doesn't either... with CNC? WTF

http://i305.photobucket.com/albums/nn212/SovXietday/block23.jpg
Hey a blockoff plate. Now I need to get my crank pulley in. From there I will fabricate a bracket for my Dseries alternator to mount up off of the plate. I will also weld on a fitting for both the water passage (big circle) and another one for the catch can (smaller circle). The water pump will push water from the bottom of the rad into that fitting and through the motor from there. Probably 12AN, but not sure yet. Need to mount of the alternator to get an idea of how much room I have to work with first.

Hopefully I'll be able to get the alternator mounted and the belt size figured out by the end of the weekend.

saxon

01-06-2012, 10:18 AM

Nice, liking the water pump but your flirting with the devil with that oil pump, esp since you can get a k20a2 pump and modify it yourself for less than 100

DaBombDiggidy

01-06-2012, 10:24 AM

how do you plan to have the transmission withstand that power? from what ive herd there arent many, if any, companies that build trasmissions for the k series motors. i also know guys who have shattered gears with 450 wheel on a roll.

2 to get into the nines do you plan on using nitrous for the first few gears? im sure that turbo will have alot of lag.

3 ive seen power made with 10 compression but wouldnt lower be easier to reduce knock?

not bashing at all im just interested in the build being a 5 year removed honda guy who had a built motor as well.

dudewheresmycar

01-06-2012, 10:45 AM

DaBombDiggidy

01-06-2012, 10:58 AM

2 step im guessing

definatly true but that jump from 10s to 9s is alot bigger then people think im sure a 100 shot in 1st/2nd with huge slicks will be a huge help into getting that 9 he wants. thinking about it the high compression will help spool that turbo as well hmm. cant wait to see this thing done.

SovXietday

01-06-2012, 12:24 PM

Nice, liking the water pump but your flirting with the devil with that oil pump, esp since you can get a k20a2 pump and modify it yourself for less than 100

The A2 pump isn't any better than the Z3 pump. Plus the Z3 pump has a "cutout" for the girdle that the A2 doesn't have. The Z3 engines stock rev limit is 8200, and a lot of flashes bump the limit to 8600. I don't see why I won't be able to get 9000 out of it without any issues, there are quite a few people who rev to 9K on stock motors even. The pumps are a big deal for the NA guys who rev to the moon, but I may not even need to go as high as 9K, it really is just going to depend on where my powerband is.

Plus have you seen stock Dseries oil pumps? Lol, I revved mine to 8700.:eek:

how do you plan to have the transmission withstand that power? from what ive herd there arent many, if any, companies that build trasmissions for the k series motors. i also know guys who have shattered gears with 450 wheel on a roll.

2 to get into the nines do you plan on using nitrous for the first few gears? im sure that turbo will have alot of lag.

3 ive seen power made with 10 compression but wouldnt lower be easier to reduce knock?

not bashing at all im just interested in the build being a 5 year removed honda guy who had a built motor as well.

I plan to replace a lot of gears. That is an honest answer, lol. There are a few gearsets available, but until I've got 2K for the 3/4 PPG gears I'll probably just be swapping stockers. There are quite a few guys running 600-700 on stock gearsets, and then there are guys running 300 and snapping gears. Kinda a crapshoot.

No, all turbo. Anti-lag will spool it up without issue.

Yes, but 10:1 is perfectly safe. Most high WHP race engines use 10.5:1 or 11 actually. Tuning has come a long way, and the higher compression setups are much more efficient than the lower ones.

PunkboySL2

01-06-2012, 12:32 PM

Sure running lower compression is easier to avoid detonation, but with more compression you will make more power per pound of boost. If I was going to build another forged motor for my car I would go 9.5:1 (stock) compression for sake of having some more low end power as well.

edit: aaron beat me to it haha.

OMGz Turbo

01-06-2012, 02:05 PM

Jeez man. You really have this thing planned out to the finest details

speedooo

01-06-2012, 03:06 PM

DaBombDiggidy

01-06-2012, 03:50 PM

http://www.clubrsx.com/browse/clubep3/?fMake=Honda+Civic&fCategory=Transmission+%3E+Gear+Sets&universal=yes&limit=30

I believe BoostedJeff told you to boost that forged 10:1 gsr you had...should've listen to him lol

he did. then i sold it and the duder wrecked it 2 weeks later.

Chris B.

01-06-2012, 04:23 PM

Step 6: Fuel System

Dual Bosch 044
1600CC injectors
FJO injector driver
8AN feed/6AN return
Normal FPR/Fuel Rail setup.

Not really sure if I'm going to build my own fuel cell and go with a sump setup, or just work from the stock tank yet. Also don't know if I'm going to stay E85 or switch back over to gas and C16. Depends on when I max those injectors, I refuse to buy $1000 ID2000s.

If you are fabrication your own manifolds, can you make a manifold that uses 2 injectors per cylinder or won't the engine management allow for that? I've seen two injectors per cylinder used on other I4 turbo cars in the past when larger injectors were either expensive or hard to get.

SovXietday

01-06-2012, 06:39 PM

Jeez man. You really have this thing planned out to the finest details

Haha, well I hope that's a good thing.

If you are fabrication your own manifolds, can you make a manifold that uses 2 injectors per cylinder or won't the engine management allow for that? I've seen two injectors per cylinder used on other I4 turbo cars in the past when larger injectors were either expensive or hard to get.

Ah the beauty of 1600cc injectors is that they're easy to find. Although, I don't believe that Hondata is capable of running 8 injectors anyway so that's kind of out. The fuel system really is where a lot of my questions still lie, but it's not time to address that quite yet.

Got the head in today. Once I remove all of the GODDAMN PACKING PEANUTS (yeah seriously....) I'll post up some pics. I seriously don't think some people have brains.

Reds82

01-06-2012, 11:20 PM

Got the head in today. Once I remove all of the GODDAMN PACKING PEANUTS (yeah seriously....) I'll post up some pics. I seriously don't think some people have brains.

gas works great on packing peanuts :rolleyes:

saxon

01-06-2012, 11:53 PM

if your doing 1600cc you might as well jump up to the id 2000's

saxon

01-06-2012, 11:56 PM

The A2 pump isn't any better than the Z3 pump. Plus the Z3 pump has a "cutout" for the girdle that the A2 doesn't have. The Z3 engines stock rev limit is 8200, and a lot of flashes bump the limit to 8600. I don't see why I won't be able to get 9000 out of it without any issues, there are quite a few people who rev to 9K on stock motors even. The pumps are a big deal for the NA guys who rev to the moon, but I may not even need to go as high as 9K, it really is just going to depend on where my powerband is.

Plus have you seen stock Dseries oil pumps? Lol, I revved mine to 8700.:eek:

I plan to replace a lot of gears. That is an honest answer, lol. There are a few gearsets available, but until I've got 2K for the 3/4 PPG gears I'll probably just be swapping stockers. There are quite a few guys running 600-700 on stock gearsets, and then there are guys running 300 and snapping gears. Kinda a crapshoot.

No, all turbo. Anti-lag will spool it up without issue.

Yes, but 10:1 is perfectly safe. Most high WHP race engines use 10.5:1 or 11 actually. Tuning has come a long way, and the higher compression setups are much more efficient than the lower ones.

ya stock d pumps are a joke, the a2 pump does not have balance shafts which will also gain you a good amount of power up high

contact shaun quickel as he built a couple k series transmissions with albins gears with great success

SovXietday

01-07-2012, 09:51 PM

if your doing 1600cc you might as well jump up to the id 2000's

ID2000s are not a "jump," they are a leap, bound, and a burning of the wallet. $1000 for injectors is justifiable if you're trying to be a competitive racer, not a college student trying to have fun lol! I can get Precision 1600s for $350 used and have them cleaned and tested for less than $50. Serving big horsepower setups for years before the IDs, I think they will do me just fine. :cool:

I'm looking into the A2 pump still, trying to figure out how much of a PITA it's going to realistically be to swap over. May not be worth the effort.

Also looking into the albins stuff, regardless it will all have to wait. I may just run the setup at a lower boost to save going through transmissions until I can afford to get the money to get the trans I want. The trans is one of those things where I don't want to bother buying it unless it's exactly what I want, till then I'll break things and have fun figuring out what's weak and what's not in a K trans, lol.

Reds, thanks for the heads up on gas! May have to give it a try, although I did get most of them out. Although, dunno if gas will help with what else I found in the head.:eek:

Onto the pics.

http://i305.photobucket.com/albums/nn212/SovXietday/block24.jpg
You can see all the bits of styrofoam and whatnot everywhere. I got most of it out, but I have to remove the rockers to bolt the head on so I'll finish cleaning it out when I get to that point.

http://i305.photobucket.com/albums/nn212/SovXietday/block25.jpg
Hmm, what's that?

http://i305.photobucket.com/albums/nn212/SovXietday/block26.jpg
LOL! Yeah, that is seriously what I pulled out of the head. Guess I found all of the bolts I need to put my timing chain cover on huh.

http://i305.photobucket.com/albums/nn212/SovXietday/block27.jpg
Crank pulley is in, so time to build my alternator mount.

http://i305.photobucket.com/albums/nn212/SovXietday/block28.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block29.jpg
Welded

http://i305.photobucket.com/albums/nn212/SovXietday/block30.jpg
Test fitting (I can use washers to shim as needed)

http://i305.photobucket.com/albums/nn212/SovXietday/block31.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block32.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block33.jpg
Was kinda mad, the weld was going nicely when I ran out of filler. The next filler rod I got must have had something on it because it didn't turn out as nice. :mad: Note to self, clean the damn filler rod.

http://i305.photobucket.com/albums/nn212/SovXietday/block34.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block35.jpg
Final fit. It's not bad at all really, once I get the hardware for the bottom figure out it should work just fine. :)

My version also moves the alternator down lower so that I have a lot more run to run the water lines. I'm also able to use the stock Dseries alternator belt because I was able to place it so close to the pulley. Pretty happy with it, just need to get the new alternator, correct bolts, do a little drilling and a quick shim and it should be golden. :)

http://i305.photobucket.com/albums/nn212/SovXietday/block36.jpg
Wooot.

saxon

01-07-2012, 09:59 PM

awesome little mount ya have there

I did the conversion for the a2 pump and i didnt have much more than a hand grinder lol, its very easy and worth it IMO

i understand the price for the injectors, but at the same time i think that ID's are worth every penny for the driveability/hp gains

SovXietday

01-07-2012, 10:16 PM

Really? What's involved with the A2 pump? I could probably sell my Z3 pump to someone who wants to go K24 fairly easily. Just need to grind down the housing right?

I agree with you for the IDs, I think they're an awesome injector. But the way I see it is, with this kind of project and my current budget there are some sacrifices that I need to make. The only thing going with 1600s will cost me is driveability and a few horsepower. It's a track car so **** driveability, and a few hp I can always makeup. Such is the cost of using cheaper injectors, but compare that with cheaping out on a fuel pump, turbo, or valvetrain.

Same thought process applies to the trans. Breaking a gear or an axle doesn't ruin my whole setup, just my day. So "dealing" with the cheaper stuff till I can upgrade is ok. ;)

The alternator bracket was fun though, thanks!

Reds82

01-08-2012, 02:08 AM

Reds, thanks for the heads up on gas! May have to give it a try, although I did get most of them out. Although, dunno if gas will help with what else I found in the head.:eek:.

Haha hope you didnt take me seriously that makes poor mans napalm. I great build thread so far seems to be coming together fast

Vince@R/TTuning

01-08-2012, 11:07 AM

Hey Aaron, welding lookin good and I'm looking forward to this coming together.

I would add some bracing to that altenator bracket. Steel you could probaly get away with like that but the alumium needs a lil more support. Like the factory ones that always seem to add that extra webbing on all the alumium brackets...

OMGz Turbo

01-08-2012, 11:32 AM

Haha, well I hope that's a good thing.

Ah the beauty of 1600cc injectors is that they're easy to find. Although, I don't believe that Hondata is capable of running 8 injectors anyway so that's kind of out. The fuel system really is where a lot of my questions still lie, but it's not time to address that quite yet.

Got the head in today. Once I remove all of the GODDAMN PACKING PEANUTS (yeah seriously....) I'll post up some pics. I seriously don't think some people have brains.

Oh i meant it in a good way lmao. It makes my pee pee hard just thinking about this cars potential

DPancoast

01-08-2012, 12:04 PM

Looks great man. keep it up

SovXietday

01-09-2012, 12:00 AM

Haha hope you didnt take me seriously that makes poor mans napalm. I great build thread so far seems to be coming together fast

LOL, well glad I didn't try. :-p Hopefully I can keep up the pace a bit, I would really like to have the engine in by summer and get to start working on building the turbo setup.

Hey Aaron, welding lookin good and I'm looking forward to this coming together.

I would add some bracing to that altenator bracket. Steel you could probaly get away with like that but the alumium needs a lil more support. Like the factory ones that always seem to add that extra webbing on all the alumium brackets...

Thanks Vince, much appreciated!

As for the bracing, well check out the $300 CNC kit.

http://k-tuned.3dcartstores.com/assets/images/products/cooling/waterplate/kwp-pk-203_1.jpg

Not a whole lot going on is there, lol.

Oh i meant it in a good way lmao. It makes my pee pee hard just thinking about this cars potential

LOL! Thanks man.

92awdtsi

01-09-2012, 12:13 AM

you should make a few extra ones yourself and sell em for $100ea. :mrgreen:

Vince@R/TTuning

01-09-2012, 11:16 AM

Thanks Vince, much appreciated!

As for the bracing, well check out the $300 CNC kit.

http://k-tuned.3dcartstores.com/assets/images/products/cooling/waterplate/kwp-pk-203_1.jpg

Not a whole lot going on is there, lol.

^^^ I agree....I think that is a lil laking in bracing as well. I mean it is a drag car so it will have limited time so you will prob be alright. I wouldn't run it on a road race car though...

SovXietday

01-09-2012, 08:26 PM

you should make a few extra ones yourself and sell em for $100ea. :mrgreen:

LOL, gotta fund this project somehow right? :-p

^^^ I agree....I think that is a lil laking in bracing as well. I mean it is a drag car so it will have limited time so you will prob be alright. I wouldn't run it on a road race car though...

Nah, I'd probably run the stock housing and water pump if it was a road race car. Prolonged vibrations might work harden the aluminum and make it brittle enough to break, but it would takes years of constant abuse to get that bad. Mind, 6061 has a 40,000psi yeild strength, and welded sections are still up at 8,000psi, so it's still pretty strong stuff. Takes a lot of force to overcome something like that.

Final look with the new alt. I used a 1/2" bolt on the bottom mount, so I had to drill out the alt mounting to make it fit. No big.

http://i305.photobucket.com/albums/nn212/SovXietday/block37.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block38.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block39.jpg

sleeperSL2

01-09-2012, 08:40 PM

you sir, do awesome work.

SovXietday

01-14-2012, 01:53 AM

Thanks Kyle!

So it's been kinda slow, waiting for parts and what not to get here. Still waiting on my pistons, so I've been just kinda at a stand still as far as the block build. Got stuff like an intake that I'm using for parts (cutting the flange off of it to make my own) and little stuff like sensors and a tensioner blah blah blah. All the boring stuff haha.

Picked up a base RSX transmission for a pretty good price. Should be here Monday or Tuesday. Once my turbo sells I'll use that money to get my twin disc. Will also crack the trans and replace some bearings as well as install the OBX LSD.

Reason I'm going with the OBX LSD
- As far as I know, it's never been tested at my power goal. I'm volunteering myself to give it a whirl.
- After a rebuild, it should be pretty damn strong.
- The differentials receive very little load and are not likely to be a part that fails. Should take the teeth clean off a gear before I ruin an LSD that is working correctly.

SovXietday

01-14-2012, 07:07 PM

Got my pistons in today! Went to assemble them so that I could start getting things moving... annnnnd the wrist pins don't fit in the rods. Guess I need to figure out what to do now, lol. If I remember correctly it's common practice is to have a machine shop size the rod end for the wrist pin to insure correct clearance. Guess I need to research some stuff.

saxon

01-15-2012, 12:17 AM

my k series rods needed to get bored for the pins also, no biggie

sundaybikes

01-15-2012, 04:26 PM

why not a spool instead of the lsd?

SovXietday

01-15-2012, 09:16 PM

my k series rods needed to get bored for the pins also, no biggie

Cool, that's what I thought. Taking everything to the machine shop tomorrow morning.

why not a spool instead of the lsd?

Last thing I want to do is break an axle and get pulled into the wall, LSD will not allow that to happen.

Asif22

01-16-2012, 10:55 AM

^ Very good point

SovXietday

01-16-2012, 07:46 PM

Scary thought though isn't it? Sending 800hp suddenly to one wheel instead of two, lol.

Dropped the rods and pistons off at a local machine shop, should have them back within the next few days so I can get moving. Just dropped a big ass order of totally random crap at Honda that was far too expensive, but I shouldn't have anything else to buy anymore! Also bought myself a torque wrench and a bolt stretch gauge. Probably best to stop stealing my pops tools when he uses them every day. :P

Transmission will hopefully be here tomorrow as well!

sleeperSL2

01-16-2012, 07:49 PM

My lord, moving at a pretty good clip I see haha. Glad to see things coming together nicely.

DPancoast

01-17-2012, 04:29 PM

now thats an update!

SovXietday

01-20-2012, 10:05 PM

Got the rods/pistons back.

http://i305.photobucket.com/albums/nn212/SovXietday/block40.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block41.jpg

Woot! Those wrist pin clips were a BITCH, my fingers are killing me lol.

Transmission also came in yesterday. Going to size up my bearings this weekend, order on monday, and start assembling stuff maybe this week.

Measured up the pistons, PTW clearance is .0025-3" across the board, so happy there.

Also decided against getting the OBX LSD. Just decided to check myself and not play around too much with inexpensive parts. So I'm going with an Mfactory LSD which are rated at over 1000whp. More than good enough for me. Still will probably rock cheap axles though, but they're easy to replace lol.

Should have just about everything I need as far as the engine/trans goes either coming or here by the end of next week. Pretty cool! Then this build is going to hit a wall hahaha, running out of stuff to sell pretty fast! But that's ok, I really can't even work on the car until it gets a little warmer, so I can just focus on sourcing all the swap parts I need from there. Slowly but surely!

Next update will be bearing sizing!

SovXietday

01-22-2012, 01:17 AM

Got the bearings figured out today, I'm going to order them on Monday and I should have them by Tues/Wed. Should be getting my big box of Honda goodies on Tuesday as well, so hopefully everything will just go together real quick here!

DPancoast

01-22-2012, 11:18 AM

Good call on using mfactory over obx. Not such good reviews from what I've been reading

jesse096

01-22-2012, 09:58 PM

Buy nice, or buy twice.

-Jesse

SovXietday

01-23-2012, 09:07 PM

Buy nice, or buy twice.

-Jesse

Exactly. It's tough, I have an OBX in my current DD and had an OBX in the hatch. However, 3 years ago, they could feasibly hold 800whp. Now? Looks like everyone who used to love them now hates them as the new ones simply fall apart. Hence my choice to go with an Mfactory unit instead.

It's a little daunting when I look at what I WANT to do and what it costs vs what I CAN do and what it STILL costs. I knew this going in obviously, but it's still pretty rough lol.

Bearings will be in tomorrow, so depending on how things go I might be putting it together Thursday. :)

SovXietday

01-24-2012, 03:17 PM

Bored so here are some pics.

http://i305.photobucket.com/albums/nn212/SovXietday/block42.jpg
Starting out. Old bearings for plastigauging. (I also mic'ed everything, but this is pretty much proof that I'm right).

http://i305.photobucket.com/albums/nn212/SovXietday/block43.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block44.jpg
Make sure if you do it on a Honda to use GREEN plastigauge. None of the other colors can read tolerances that are fine enough.

http://i305.photobucket.com/albums/nn212/SovXietday/block45.jpg
.0015 is a winner.

Ended up being all greens (factory was all browns), makes it easy. If you're not familiar, Honda has a bunch of different bearing sizes that are color coded. Green is right in the middle, with brown being the next larger bearing.

Here's the head.

http://i305.photobucket.com/albums/nn212/SovXietday/block46.jpg

That's a K24 IM that I will be cutting apart and using the flanges off of to make my own. Should be quite the interesting endeavor, lol. When I finally get to that point of course.

And of course, the transmission.

http://i305.photobucket.com/albums/nn212/SovXietday/trans1.jpg

Mfactory LSD is in the mail, so I will be tearing this guy apart soon to install that. Excited, can't wait to see what's different in the K trans compared to the D trans. :)

russiankid

01-24-2012, 05:56 PM

Awesome build! I think you'll be fine with that alternator bracket. I have seen some old Chevy's with 350's that have thinner metal brackets from factory. All it does is hold the alternator in place and keep tension.

SovXietday

01-26-2012, 07:40 PM

Thanks man! Yeah, I think it will be just fine. If I'm wrong, it'll just bend and throw the belt. Still don't think it's likely though, I've taken a prybar to it for fun and all I did was end up on my ass. :lol:

Pretty big update! I've got quite a big portion of the block together.

But first, looky looky what came in the mail today.

http://i305.photobucket.com/albums/nn212/SovXietday/trans2.jpg

Woot.

Ok ok.

http://i305.photobucket.com/albums/nn212/SovXietday/block47.jpg
Quick hone.

http://i305.photobucket.com/albums/nn212/SovXietday/block48.jpg
And begin.

http://i305.photobucket.com/albums/nn212/SovXietday/block49.jpg
I decided to document putting together one of the cylinders, just for fun.

http://i305.photobucket.com/albums/nn212/SovXietday/block50.jpg
Measuring ring end gap. This was the top ring, I also did the bottom ring. Ring gaps were measured as per Wiseco instructions. Bore size x .006 and +.004 for 2nd ring. So that's .021 -.022 for top and .026 2nd ring.

http://i305.photobucket.com/albums/nn212/SovXietday/block51.jpg
My piston ring arrangement reference.

http://i305.photobucket.com/albums/nn212/SovXietday/block52.jpg
Spring compressor that I HAAAAAATE. Dumbest design ever.

http://i305.photobucket.com/albums/nn212/SovXietday/block53.jpg
In we go.

http://i305.photobucket.com/albums/nn212/SovXietday/block54.jpg
Woo I didn't bend anything! :-p

http://i305.photobucket.com/albums/nn212/SovXietday/block55.jpg
Getting ready to slide the bearing on and get it on the journal.

http://i305.photobucket.com/albums/nn212/SovXietday/block56.jpg
Not surprisingly, on the journal.

http://i305.photobucket.com/albums/nn212/SovXietday/block57.jpg
Luuuuuube son.

http://i305.photobucket.com/albums/nn212/SovXietday/block58.jpg
Bolted in! I wasn't able to use my bolt stretch gauge. Couldn't get it to fit, nor could I see the damn depression to put the gauge in.

http://i305.photobucket.com/albums/nn212/SovXietday/block59.jpg
And it's in.

http://i305.photobucket.com/albums/nn212/SovXietday/block60.jpg
Shiny.

http://i305.photobucket.com/albums/nn212/SovXietday/block61.jpg
Oil pump and chain all put together.

http://i305.photobucket.com/albums/nn212/SovXietday/block62.jpg
Bottom end complete.

http://i305.photobucket.com/albums/nn212/SovXietday/block63.jpg
Just because I like this pic.

http://i305.photobucket.com/albums/nn212/SovXietday/block64.jpg
Turning to getting the head on.

http://i305.photobucket.com/albums/nn212/SovXietday/block65.jpg
Stripping down the head. Can't get to the head bolts without it.

http://i305.photobucket.com/albums/nn212/SovXietday/block66.jpg
Nice view of the dual valve springs and Ti retainers.

http://i305.photobucket.com/albums/nn212/SovXietday/block68.jpg
Head ports, mmmm.

http://i305.photobucket.com/albums/nn212/SovXietday/block67.jpg
Head bolted down at 80ft/lbs, and the rockers are all set in with their dowels.

http://i305.photobucket.com/albums/nn212/SovXietday/block70.jpg
So this is where I'm at. I need to polish the journals on the intake cam because they have a bit of buildup on them. Little emry cloth and it should be good to go.

Well, we're getting there lol.

Proven

01-26-2012, 08:28 PM

Amazing work man! Def. hope to see this thing live at some events come summer.

SovXietday

01-27-2012, 07:19 PM

Thanks man, haha. If by summer you mean next summer I think we have a chance. No way I'll get this done before then I don't think. :(

Proven

01-28-2012, 05:34 PM

Thanks man, haha. If by summer you mean next summer I think we have a chance. No way I'll get this done before then I don't think. :(

WHAT? I can't wait that long!

Messing of course, take your time and keep doing it like you have been.. The right way!

No build thread on k20a.org?

SovXietday

01-28-2012, 09:52 PM

Hahahaha, me neither man! But I want to do it with solid parts so gotta take my time. :)

There is a build thread on K20a, it's in the EG/EK section, but this one will probably be a lot better. :)

ketchup!

01-29-2012, 01:10 AM

awesome work aaron. might have you build me a block in the future :)

SovXietday

01-29-2012, 12:27 PM

Thanks bud, sounds good. :)

biggard09

01-29-2012, 11:47 PM

build looks amazing man.. awesome fab work!

SovXietday

02-03-2012, 11:50 PM

Thanks man! I can't wait to get to the really fun fab work. :)

So a few developments. I got the cams in, timed the motor, and was ready to go. But just have been having a gut feeling about that damn oil pump. So the motor has been just sitting for the past week while I've been doing tons of research and trying to make up my mind. Pretty much have come to the conclusion that I need to get the ERL S2K pump. Just not worth trying to use the Z3 pump, and the A2 pump is a waste of money for what I want to do. So, 9500rpms here I come! Just need to close my eyes when I order it later this week, lol.

Don't have any pictures at the moment, but I jumped on a set of mounts that I NEVER thought I'd find used. They are Hybrid (Innovative) 100% solid billet EKK1 mounts. Got them for a damn good price too, just couldn't pass it up. Also have a lead on a CCtwin disc that I'm probably going to jump on, but we'll see if it works out. But, looks like the motor will be in the car this spring. Won't run, but it will be in so I can begin a lot of the fab work and such over the summer.

As of right now, just want to get these two big purchases out of the way, finish and button up the engine, install the diff in the trans, clean/paint engine/trans, get a wire harness and start wiring the engine. That will do for me until the weather breaks and I can't get the engine mocked up in the car!

DPancoast

02-05-2012, 12:03 PM

So awesome man! I'm excited to get my mfactory LSD as well.

Don't have to worry about all that power like you do tho :P. good luck! Let me know if you need help putting the motor in!

SovXietday

02-10-2012, 03:24 AM

Thanks Dan! Finally got the motor finished up today after dealing with my oil pump dilemma.

Bounced back and forth between keeping my Z3, going to an A2, or just going all out with the S2K pump. Z3 was easy, but I was seriously concerned about the speed at which it was going to turn (it's a 2:1 ratio, which means at 9K the pump would be spinning at 18K rpms!) and the balancers stealing oil pressure. Then it was between the A2 pump cavitating around the 9K mark, and the S2000 pump being so insanely expensive (500 for just the pump, not including the windage tray/chain/tensioner/K24 pan). After talking to a few shop owners who have run the A2 pump to 9K and above with no issues, I decided that it would be the best option for me. So, ordered a new one and got on with it.

http://i305.photobucket.com/albums/nn212/SovXietday/block71.jpg
All the new stuff.

http://i305.photobucket.com/albums/nn212/SovXietday/block72.jpg
The brand spankin' new A2 pump.

http://i305.photobucket.com/albums/nn212/SovXietday/block73.jpg
This originally is the location of the oil restricter which feeds the Z3 balance shafts. I had to remove the restricter and plug it with a bolt, otherwise I'd get next to no oil pressure at all. I used a 1" long M8 x 1.25 bolt, tapped the hole out, and used a good amount of teflon tape on the bolt threads.

http://i305.photobucket.com/albums/nn212/SovXietday/block74.jpg
Time to install the pump. Yeah, that doesn't fit so hot does it? Lol.

http://i305.photobucket.com/albums/nn212/SovXietday/block75.jpg
Little grinding and shaving. About 10 minutes total.

http://i305.photobucket.com/albums/nn212/SovXietday/block76.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block77.jpg
Actually fit pretty damn snug, was happy with that.

http://i305.photobucket.com/albums/nn212/SovXietday/block78.jpg
Surprisingly the windage tray had a hole already cut out for this bolt. Works for me! Don't know why guys switch to an M10 bolt, a long enough M8 will do just fine and you don't have to drill the hole bigger.

http://i305.photobucket.com/albums/nn212/SovXietday/block79.jpg
Bottom end completed.

http://i305.photobucket.com/albums/nn212/SovXietday/block80.jpg
All done! Just need to button it all up.

http://i305.photobucket.com/albums/nn212/SovXietday/block81.jpg
This is the block portion of the heater hose outlets. So I wanted to block that off (obviously not running them).

http://i305.photobucket.com/albums/nn212/SovXietday/block82.jpg
Easy as that! Not the prettiest weld, but it works. A little black paint will rustproof it and its a free plug.

http://i305.photobucket.com/albums/nn212/SovXietday/block83.jpg
Completed!

I have a few things to work out. Bolted the crank on today to realize it was sitting right up against the chain case cover. Figured there had to be a spacer, and found out I'm still missing the crank pulse plate. Dammet. I'll have to find that and replace it. Once I do it should be all kosher finally. The oil pan and valve cover are not done yet, I ordered a bunch of weld on AN fittings tonight. I will be able to weld on my catch can and oil drain fittings, then I will be able to make it looks pretty and bolt it all together permanently.

I also found a sick deal on a lightly uses CC twin disc! That is currently in the mail and on its way, so I'm excited about that for sure!

Lastly, I started cutting apart the old K24 manifold that I bought. Basically I'm cutting the head flange off of it and will be building an entire manifold off of that. :)

That's all I've got for today.

DPancoast

02-10-2012, 08:16 AM

I hate how fast your builds go lol. I don't care what you say.

SovXietday

02-15-2012, 09:01 PM

Hahaha, well it never seems to go fast enough.

So I got a little welding in today. Feels good to get behind the torch.

http://i305.photobucket.com/albums/nn212/SovXietday/block85.jpg

Remember that K24 IM that I had? Well it was the source of my (albeit rough) flange for my new intake manifold. No where near done, lots of work to do still. But I'm not there yet either.

http://i305.photobucket.com/albums/nn212/SovXietday/block86.jpg
Before

http://i305.photobucket.com/albums/nn212/SovXietday/block87.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block88.jpg
After, and my nicest of the three welds (I hate welding cast).

http://i305.photobucket.com/albums/nn212/SovXietday/block90.jpg
Oil pan turbo drain prepped.

http://i305.photobucket.com/albums/nn212/SovXietday/block91.jpg
And welded up.

Then I welded the fittings onto my water pump blockoff.

http://i305.photobucket.com/albums/nn212/SovXietday/block92.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block93.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/block94.jpg
A 90* fitting should fit perfectly on that without any issues.

http://i305.photobucket.com/albums/nn212/SovXietday/block95.jpg
Oh yeah. :)

http://i305.photobucket.com/albums/nn212/SovXietday/trans3.jpg
My CC twin! It was used for a dyno tune and that's it.

http://i305.photobucket.com/albums/nn212/SovXietday/trans4.jpg
Trans is up on the bench and ready for tear down. I had to find a 12mm allen head so I could get the c-clip bolt off so I'll be probably getting that apart tomorrow. Once the diff is in I will clean everything up and paint the trans/engine and make it looks all nice like.

I have a wire harness coming, so I can wire the engine up out of the car. I'm pretty much going to probably rewire the whole car this time since I won't be needing stuff like lights/signals/etc.

...think the next thing on my buy list is a turbo. :) I have everything to mock the engine up in the car, so it's time to start getting the turbo kit together so I can start fabricating!

DPancoast

02-15-2012, 09:41 PM

Awesomeeeee!

SovXietday

02-20-2012, 02:23 AM

Finally got the last thing I needed to completely finish the block. So it's finally done until I blow it up right? Put the timing chain cover and oil pan on permanently (if I keep saying it it'll be true right?) tonight finally.

Also got my wire harness in the mail today. Looks just fine, so whenever I find some free time I'm going to start stripping it down and start getting it fitted on the block.

Trans is sitting on my bench until I can get the damn 14mm allen key to get the stupid spring cap off. I'm sure it will give me a ton of **** trying to get it off, can't wait.

Might pull the trigger on a turbo tomorrow, but still debating with myself. Trying to decide between going with a 6266 or a 6766. I can get my goal with the 62, but the 67 lets me grow. IDK, $200 difference.

92awdtsi

02-20-2012, 10:18 AM

Might pull the trigger on a turbo tomorrow, but still debating with myself. Trying to decide between going with a 6266 or a 6766. I can get my goal with the 62, but the 67 lets me grow. IDK, $200 difference.

Honestly, your gonna be kicking yourself if you don't spend the extra $200 and have room to grow.... Having things that you may not ever use is ALWAYS better than needed/wanting it and not having it.

saxon

02-20-2012, 11:13 AM

67 is a 8 second turbo, 62 is a 9 second turbo

Both seem more than fast enough

JST2KWIK

02-20-2012, 01:37 PM

Wilzfab FTW!

SovXietday

02-20-2012, 02:23 PM

Honestly, your gonna be kicking yourself if you don't spend the extra $200 and have room to grow.... Having things that you may not ever use is ALWAYS better than needed/wanting it and not having it.

67 is a 8 second turbo, 62 is a 9 second turbo

Both seem more than fast enough

I hear ya Gody, but the 62 will do quite a lot and that $200 can build my entire intake manifold! Plus, I will have a nice big powerband with the 62, and 9s are going to be well within reach (I think the current record is 9.6s). Nutty.

Wilzfab FTW!

Hahahaha. Thanks for sending your friend to me dude, hope he was happy.

JST2KWIK

02-20-2012, 02:30 PM

Hahahaha. Thanks for sending your friend to me dude, hope he was happy.

Anytime thanks for hooking him up, he was thrilled!! The welds looked great :supz:

92awdtsi

02-20-2012, 02:33 PM

I hear ya Gody, but the 62 will do quite a lot and that $200 can build my entire intake manifold! Plus, I will have a nice big powerband with the 62, and 9s are going to be well within reach (I think the current record is 9.6s). Nutty.

Hahahaha. Thanks for sending your friend to me dude, hope he was happy.

lol well if you can have a 9 sec turbo and build your IM, then by all means go for it

csmit27

02-20-2012, 10:09 PM

looks good brother!

SovXietday

02-20-2012, 10:09 PM

Anytime thanks for hooking him up, he was thrilled!! The welds looked great :supz:

Thanks buddy. :cool:

lol well if you can have a 9 sec turbo and build your IM, then by all means go for it

I'm still thinking on it trust me, most people are telling me to just get the 67 and enjoy it so I'll probably go with that. Even the guy who has the record on the 62 said he'd rather have a 67 lol. Only money right?

SovXietday

02-26-2012, 10:28 PM

Quick update. Actually got to work on the car a little bit!

http://i305.photobucket.com/albums/nn212/SovXietday/bay1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bay2.jpg
Ew.

http://i305.photobucket.com/albums/nn212/SovXietday/bay3.jpg
Stripped it down, ready for a little bit more work and a brake tuck.

http://i305.photobucket.com/albums/nn212/SovXietday/wiring1.jpg
Started on the wiring a little bit. Not much I can really do with it at the moment though. Really need to get the engine in the car so I can figure out placement of stuff.

http://i305.photobucket.com/albums/nn212/SovXietday/oilfeed-002.jpg
Some of you may remember my old oil feed setup. It lets me monitor oil pressure at the CHRA. I wanted to modify it a little bit, so this is what I've got so far.

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock3.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock4.jpg
Setup is pretty simple. Oil feeds into the black manifold and has to go through a .065 restrictor. The gauge on top reads output pressure, which will be the same at the turbo CHRA. As far as the interesting fittings, if they're not familiar to you, they are tube nuts for hardline. :)

Once my 34 degree flare kit comes in I will start bending up some line and also start my brake tuck.

jesse096

02-27-2012, 12:33 AM

What exactly is a CHRA?

-Jesse

Forc3 F3d

02-27-2012, 03:34 AM

What exactly is a CHRA?

-Jesse
center housing rotating assembly of the turbo.

jesse096

02-27-2012, 09:07 AM

Aha, I knew it had to be something with the turbo lol, thanks!

-Jesse

davin

02-27-2012, 09:41 AM

Neat!

Tischu_Box

02-27-2012, 10:09 AM

Love the details!

DPancoast

02-27-2012, 02:46 PM

Awesome update. Can't wait to see moarrrrr

SovXietday

02-27-2012, 09:10 PM

Thanks guys! I'm going to try to get the line bent up tonight or tomorrow. Got my rather expensive 37* flare tool today only to find out that the description on Amazon was wrong and that it can't flare stainless lines. Sooo... guess I'm gonna have to wait to actually flare stuff. :/ Gotta go through the whole return and buy a new one process now, sucks.

Still waiting on one of my nicer items that's in the mail right now. Can't wait for that. :)

jesse096

02-28-2012, 12:21 PM

Doesn't stainless steel require a different flare angle? I thought you could only do like a 27* single flare?

-Jesse

SovXietday

02-28-2012, 12:47 PM

Doesn't stainless steel require a different flare angle? I thought you could only do like a 27* single flare?

-Jesse

Hard lines are actually pretty simple. Doesn't matter what material you're using, it has to do with the fittings.

Standard inverted fittings, like the ones you'll find on your stock brake lines and what not, are all 45* fittings. Mild steel needs a double flare (it's a single flare but "turned back" on itself), stainless steel is strong enough to only need a single.

AN fittings use 37* angles, just to make things complicated. Same rule applies, mild/Al should double flare, stainless only needs single.

MUST use steel for brake fittings. Bulkheads/hardware included. Steel fittings look nice, and are cheaper, so I'm probably just going to use that finish throughout the build.

The flare kits you find at Autozone can't do stainless, so you have to buy much more expensive ones (cheapest I've found is around $125). Since most of everything I'm doing will be AN I will be able to do most of my flaring with that tool though, so it's worth it in the end.

Hope that answers everything.

jesse096

02-28-2012, 01:53 PM

Damn, you wrote a book for me! LOL That answered everything for me, thank you!

-Jesse

SovXietday

02-28-2012, 04:07 PM

Hahaha, no sweat man. Glad I could answer your question.

DPancoast

02-28-2012, 04:37 PM

Just make sure you clamp down that flare tool! Sometimes it won't seal good. Don't ask me how I know

hammtheman

02-28-2012, 08:44 PM

dude awesome build!!

i cant agree with dan any more. The company i work for built a few overhead cranes with a hydraulic system that used all stainless hard pipe with flares. i couldnt even count how many times i had to put in these plastic inserts to help smooth out the flare. Make sure that the pipe is clean and you flare it straight, it such a damn headache. but subscribed for sure....good ****

SovXietday

03-02-2012, 10:57 PM

Hahaha, yeah dude I hear you guys no worries. We will see how things work out, so far my flare tool has really impressed me. Well worth the little bit of extra money that I spent for it. Obviously I won't know how well this stuff holds pressure until I get things working, but we'll deal as needed.

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock6.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock7.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/oilblock8.jpg

I think it came out pretty nice for my first time doing hard lines.

Also got the bearings on the diff so it was time for an install.

http://i305.photobucket.com/albums/nn212/SovXietday/trans7.jpg
Mfactory diff in.

http://i305.photobucket.com/albums/nn212/SovXietday/trans8.jpg
All the internals assembled.

http://i305.photobucket.com/albums/nn212/SovXietday/trans9.jpg
Case together. These transmissions are 100x easier to reassemble than those damn Dseries ones. Love it.

I would really like to get the engine in the car over spring break. If that doesn't happen I probably won't be able to do it for a while.

So, with that, gotta make it look pretty right?

http://i305.photobucket.com/albums/nn212/SovXietday/block96.jpg
Primered.

http://i305.photobucket.com/albums/nn212/SovXietday/block97.jpg
Painted!

That's all I've got for right now. Tryin to keep things moving lol.

rocknrace03

03-02-2012, 11:03 PM

is that duplicolor stainless steel paint? i just used it too. its amazing how good it looks hahah nice build man, love your fab work, so excited to learn to big over spring break

DPancoast

03-02-2012, 11:43 PM

Nicccce. Totally didn't need to see that pic of the trans internals. My mfactory stuff is staring me in the face in the living room now lol

Slevin

03-03-2012, 12:56 AM

amazing work

SovXietday

03-09-2012, 11:48 PM

is that duplicolor stainless steel paint? i just used it too. its amazing how good it looks hahah nice build man, love your fab work, so excited to learn to big over spring break

It's something like that lol. I don't actually remember the color, but it came out pretty nice so I'm happy.

Well, super excited, because my turbo is here. :)

http://i305.photobucket.com/albums/nn212/SovXietday/turbobuild1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbobuild2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbobuild3.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbobuild4.jpg

Precision 6766 - Billet CEA 67mm turbo
Ported H cover 4"in / 3" out w/ antisurge inlet
1.00 A/R T4 Divided Exhaust Housing w/ 3 5/8" Vband out

Go big or go home right?

jesse096

03-09-2012, 11:52 PM

I think I just wet myself...

-Jesse

boostedfury

03-10-2012, 10:00 AM

I came......

To the conclusion that this is a badass build!

DPancoast

03-10-2012, 10:12 AM

You have to at least put up that pic of the Pepsi can next to it.

That turbo is fricken huge

SovXietday

03-10-2012, 10:40 AM

Haha you mean this one?

http://i305.photobucket.com/albums/nn212/SovXietday/turbobuild5.jpg

It is really friggen big dude, lol.

DPancoast

03-10-2012, 11:19 AM

Bingo. Makes me giggle everytime and say "no way" lol

mxguy1286

03-10-2012, 11:26 AM

Haha you mean this one?

http://i305.photobucket.com/albums/nn212/SovXietday/turbobuild5.jpg

It is really friggen big dude, lol.

Dan needs to follow the leader here....:-p

Spawne32

03-10-2012, 11:54 AM

for all the great metal work you did for customization, your build up of the block was absolutely horrible, you measured the p2w BEFORE the hone, you used clearly too rough of a grit when honing, and theres absolutely no crosshatch what so ever. Getting those rings to seat properly is going to be a bitch. Did you even check the block deck and head deck for flatness?

SovXietday

03-10-2012, 10:00 PM

Let's ask 2 questions.

1) Do you even realize what you're saying, and with what backing info are you saying it?
2) What's the last motor you built, and how long did it last?

- Measuring P2W before hone. Basically what you're saying is that my P2W clearance is now minimally larger than what I measured? Uh, k. Guess this is where you explain why that is a bad thing, using an answer other than "well it's not correct procedure." Truth is, the change in bore is not only so small I can't even read it with the tools I have, but it only adds to my margin of safety.

- Hone. This is not the first time I've used this particular honer. Might I redirect your attention to the first page where the link for my Dseries build is. Funny thing, that engine was built with the same exact tool. Never had an issue getting the rings to seat, and never had an issue with oil consumption on the motor. In fact, it never, EVER had the normal Honda "blue cloud" during pulls. Want to know something else? My dad has used that exact tool to hone 100+ Honda engines over the years. He never had any issues with it either, among the thousands of other people who have used this particular honer to do the same job. You can ask Mr. Pancoast, his motor is running on the same hone right now.

- Yes, I checked for flatness. If for some reason my straight edge wasn't perfectly straight, then I guess I have to pull the engine. Being as I'm planning on it being some 800+hp car, I don't expect it will be the last time either.

To answer part two for you, the last engine I built was my Dseries. The piston to wall clearance? .008+. Car ran for 4 years, two of which were daily driven every single day. When I broke the engine down, cylinder walls looked just fine considering after all of the abuse it took. It's now running in another car in Penn State, owner is perfectly happy with it. If I needed machine work done, I would have had the machine shop do all of the other work for me so that I could drop pistons in. No, the engine isn't built to "internet" spec. But it is built to a spec that mechanics have been using for decades and has worked out just fine for me in the past.

I'm honestly hoping that you can answer question #2 with at least a few engines under your belt, because if you haven't built one and you're chewing me out I really don't know what to say.

hammtheman

03-10-2012, 10:34 PM

i will have to agree with sov. i saw his dseries run at the r/t tuning dyno day after 4 years of abuse and the car still layed down awesome numbers and didnt smoke one bit. motor building is an art, each person and shop has their own ways for the doing the same process. if its worked on countless other motors why bust his balls. basically you compared his motor building to the way he ties his shoes.....just because it inst the way you do it, it must not work.

On another not sov that turbo is freaking huge. keep up the good work hope to see this thing out and about next year

sleeperSL2

03-10-2012, 10:44 PM

Holy big turbo.

DPancoast

03-11-2012, 07:47 PM

Dan needs to follow the leader here....:-p

My gt3251 has some shaft play suddenly. Lol. I'm either sending it out and having it upgraded or ???? :P

jesse096

03-11-2012, 09:13 PM

Big turbo LS Dan?

-Jesse

DPancoast

03-12-2012, 01:47 PM

Don't wanna clog up Aaron's thread, but I'm not sure what I'm gonna do. Getting different answers on what my turbo is efficient to.

My block is overbuilt for my current turbo for sure lol.... But I kinda like it that way. Depending on what kind of answers I get I just need injectors to turn up the boost on my current snail. Just don't know how much I can push it!

SovXietday

03-14-2012, 07:49 PM

Dan, what turbo? The GT3251? I'm pretty sure it's a 51mm turbo, so you're looking at around 400-450ish max, and that's pushing it.

Todays update kind of speaks for itself. Had to quit earlier than I wanted to, ran out of MIG wire. All I gotta say is this **** sucks.

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave3.jpg

Grinding.

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave4.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave6.jpg

Welding. Ran out of wire before I wanted to. Just gotta grab some more.

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave7.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave8.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave9.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave10.jpg

Ugh, worst part ever. Grinding these welds suck, lol. Rad support is completely welded/shaved. Just needs some filler work and some smoothing.

So far so good. I'll be the first to admit that I'm no body man. Lots of welding and plugging to go yet, I'm about 50% done when it comes to that. Try to get some more work in on Friday and Sunday. Hopefully with some care and patience (I have like none when it comes to this stuff lol) it will come out pretty nice. Debating on whether I want to do black or go white this time?

jesse096

03-14-2012, 07:51 PM

So will this be a show/drag car? Or are you shaving the bay for simplicity sake?

-Jesse

SovXietday

03-14-2012, 08:42 PM

I'm the kind of person who likes to try new things and expand my skill-sets. A lot of what I do "the hard way" is just for that reason. So consider this one of those. This is actually likely to be a bit more of a pain in my ass than helpful, but it's ok. The correct way to do this would be to get the engine in and mock up the entire thing, pull it all out, and then weld/shave everything I'm not using, rather than shaving everything and then making new holes for the stuff I'm putting in. That said, I'll just work around it when I get there.

But yes, while it will be mostly a race car, I hope to trailer it to some of the bigger local meets as well.

DC2.2GSR

03-14-2012, 09:00 PM

...

Ugh, worst part ever. Grinding these welds suck, lol. Rad support is completely welded/shaved. Just needs some filler work and some smoothing.

So far so good. I'll be the first to admit that I'm no body man. Lots of welding and plugging to go yet, I'm about 50% done when it comes to that. Try to get some more work in on Friday and Sunday. Hopefully with some care and patience (I have like none when it comes to this stuff lol) it will come out pretty nice. Debating on whether I want to do black or go white this time?

you're crazy, you're working on the best part right now! I love it.

95naSTA

03-14-2012, 09:50 PM

I love seeing that much work done to a bay.

I used pennies for some of the PITA smaller holes in my bay.

jesse096

03-14-2012, 10:38 PM

92awdtsi

03-15-2012, 07:25 AM

Debating on whether I want to do black or go white this time?

I'd go with white, (very forgiving with body work :mrgreen: )

sundaybikes

03-15-2012, 02:11 PM

battleship gray, real racecar color for a bay/interior

DPancoast

03-15-2012, 04:32 PM

Looks good so far! Can't wait to see you get done!

SovXietday

03-15-2012, 08:42 PM

I'd go with white, (very forgiving with body work :mrgreen: )

This sounds like a winner then. I have a feeling my body work won't be the best lol.

battleship gray, real racecar color for a bay/interior

Just because it's a racecar doesn't mean it has to be fricken ugly. That color sucks, lol.

Thanks guys! Sure helps to have some motivation lol.

BigWhiteTodd

03-15-2012, 09:47 PM

should chrome the bay would be sick haha, this build is looking great along with the fab skills.

DC2.2GSR

03-16-2012, 01:36 PM

should chrome the bay would be sick haha, this build is looking great along with the fab skills.

That's what I was thinking. Or gold. Gold engine bay with white exterior, or black with chrome, gold or black chrome engine bay. Seriously... I can make that happen. :mrgreen:

SovXietday

03-16-2012, 09:13 PM

Chrome? You guys are nuts, lol.

Not that metal plating other parts is out of the question. :P

SovXietday

03-30-2012, 12:56 AM

Updates are going to be slow for a while. Right now I have so much on my plate it's not even funny between work/school/gf/etc. I have been getting 3-4 hours a week to work on the car. Last week was a big debacle. Ran out of MIG wire, picked some up. Got home, didn't have the right size end for the torch, so I had to go get another one. Got one hole done and ran out of gas. It was Sunday so couldn't get more. So I ended up grinding and laying bondo on the rad support but haven't even been able to sand it since then.

Got more gas, going to try and get all of the welding out of the way tomorrow so that I can start putting on filler. I will be able to sand at night after school, but welding is a little different so hopefully I'll start making some progress here soon.

Some of you are aware, but I am now a part time welder/fabricator with PSI Proformance in Lansdale PA. So I've been getting my hands dirty with a lot of fab stuff lately, and really enjoying it. Just doesn't allow much time to work on my own stuff, lol!

blue91lx

03-30-2012, 01:53 AM

If you would've waited a dang week you could've gotten a turbo that makes more power than the 6766 and spools faster: the 6466. Looks great!

SovXietday

03-31-2012, 10:41 PM

I'm good, the 6466 looks like a nice unit but it's not offered in a journal bearing, and it still is a little short on power compared to the 67mm. Thanks though!

So I think I'm completely done with the welding and shaving. If I find any more holes that I missed I'll probably just leave them open, my MIG torch is leaking air badly and I had to just finish the rest of the welds without gas.

Now it's time for body filler and sanding, yay lol.

Hopefully I can get primer on the bitch soon.

DPancoast

04-01-2012, 02:01 PM

Excitement. I haz it.

SovXietday

04-02-2012, 10:17 PM

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave11.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave12.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave13.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave14.jpg

Hate. Every. Second.

Not to mention I have no idea what I'm doing. :P

Going to run over some of the pinholes and small stuff with glazing putty, sand, final 180grit sand, and then get ready to primer. Trying to figure out what I want to go with as for painting.

Trying to decide between dropping $$$ on a single stage paint and hoping I don't fug it up spraying it on, or just go with the cheaper duplicolor paint shop stuff (they actually have champ white) and just use that instead. Kinda leaning toward the duplicolor stuff, because apparently it's really easy to touch up, and I'm guaranteed to scratch this **** like crazy.

ketchup!

04-02-2012, 10:24 PM

civictype_r

04-02-2012, 10:46 PM

Go champ white!

DPancoast

04-02-2012, 11:01 PM

That's gonna look awesome. Do the duplicolor. It'll come out alright if you skimp on prep a little.

BigWhiteTodd

04-03-2012, 08:46 AM

no do it chrome would be siiick haha

SovXietday

04-04-2012, 12:17 PM

I think chrome is out I don't think you can plate bondo lol.

Paint this weekend? Possibility.

g0dzuki

04-04-2012, 03:21 PM

boostedfury

04-04-2012, 10:57 PM

that idea makes perfect sense...keep it the white and you can always do touch ups!

BTW, crazy props on the patience.. I do body work here and there and yeahhhh lol

92awdtsi

04-05-2012, 08:58 AM

looking good! are you going to shoot the primer out of a gun? ( save yourself so much time and you'll actually be able to mix up a high build viscosity ).

CHR!S

04-05-2012, 03:46 PM

http://www.por15.com/
:thumbup:

nissan240syan

04-05-2012, 04:35 PM

if you gonna put in all that work to get the bay looking good why not keep going with quality paint work ?

SovXietday

04-05-2012, 10:56 PM

do a lighter color ESPECIALLY if you are going to race it...why you ask?

to see any leaking fluids from the motor so you can possibly fix on the spot or easier to diagnose the problem

don't listen to some of these people lol no idea what they are talking about

Excellent point, and no worries, it'll be champ white. :)

looking good! are you going to shoot the primer out of a gun? ( save yourself so much time and you'll actually be able to mix up a high build viscosity ).

Yessir! Don't want to rattle can stuff this time around.

if you gonna put in all that work to get the bay looking good why not keep going with quality paint work ?

Mostly because in the end it's gonna be a race car, and it's going to get oil and fuel and all that good stuff all over it. Not to mention pulling the trans all the time to fix shattered gears and whatnot. Honestly? I'm at that point that I really regret even bothering to do it, just trying to finish out strong so that it looks solid, but it's not going to be show quality. Don't get me wrong, not trying to rattle can it primer and say F this! But it just doesn't need to be ZOMG pristine show quality for ME to be happy with it..

I'm kind of a DIYer, I like to try things and do it myself. Just not worth spraying $250 paint through a Kobalt gun with 25 year old wheezy air compressor, lol. As for paying for someone else, looked at that route, but just can't justify the money when it can be spent elsewhere on the car.

92awdtsi

04-06-2012, 10:17 AM

Excellent point, and no worries, it'll be champ white. :)

Yessir! Don't want to rattle can stuff this time around.

Mostly because in the end it's gonna be a race car, and it's going to get oil and fuel and all that good stuff all over it. Not to mention pulling the trans all the time to fix shattered gears and whatnot. Honestly? I'm at that point that I really regret even bothering to do it, just trying to finish out strong so that it looks solid, but it's not going to be show quality. Don't get me wrong, not trying to rattle can it primer and say F this! But it just doesn't need to be ZOMG pristine show quality for ME to be happy with it..

I'm kind of a DIYer, I like to try things and do it myself. Just not worth spraying $250 paint through a Kobalt gun with 25 year old wheezy air compressor, lol. As for paying for someone else, looked at that route, but just can't justify the money when it can be spent elsewhere on the car.

sounds to me like your best option is (and most appropriate for your skill level, just a guess dont take offense) would be to high build the balls off it, sand with 320-400 then a few coats of a single stage paint. Done

SovXietday

04-07-2012, 10:50 PM

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave15.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave16.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave17.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave18.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave19.jpg

Welp, I've got some more sanding to do lol. Still needs some work, and a few repairs to do yet. Missed some stuff because I just couldn't see it over all of the scuffs/bondo/marks etc. Really just want to get the spots that will be easily seen on the car to be really nice, the rest I'll try to clean up as best as possible but won't go crazy with.

Any suggestions on what I can use to fix pinholes and the like on lacquer based primer?

92awdtsi

04-07-2012, 10:59 PM

to fill pinholes ( might not be an "approved" method) but i've used it more times than i can count on customer cars with no issues.... while the primer is still wet and you see a pin hole, use your finger to smear/smudge the primer into the hole ( filling it in ). It will look ugly and like a run but once its dry, it will sand flat and you will never be able to tell that it was ever there.

boostedfury

04-07-2012, 11:07 PM

Looks sick and that's just primer!! Full confidence this will be awesome once completed :)

slowZ

04-07-2012, 11:43 PM

Kambi putty is what's recommended to fill pin holes and you won't have to re prime u can go strait to paint

DPancoast

04-08-2012, 10:37 AM

Looks good man!

nissan240syan

04-08-2012, 06:34 PM

Mostly because in the end it's gonna be a race car, and it's going to get oil and fuel and all that good stuff all over it. Not to mention pulling the trans all the time to fix shattered gears and whatnot. Honestly? I'm at that point that I really regret even bothering to do it, just trying to finish out strong so that it looks solid, but it's not going to be show quality. Don't get me wrong, not trying to rattle can it primer and say F this! But it just doesn't need to be ZOMG pristine show quality for ME to be happy with it..

I'm kind of a DIYer, I like to try things and do it myself. Just not worth spraying $250 paint through a Kobalt gun with 25 year old wheezy air compressor, lol. As for paying for someone else, looked at that route, but just can't justify the money when it can be spent elsewhere on the car.[/QUOTE]

That definetly makes sense now if thats what you plan to use the car for and respect for that aswell. Good Luck !

SovXietday

04-08-2012, 09:10 PM

Thanks guys! Hopefully I'll be able to get color on next weekend. :)

SovXietday

04-20-2012, 06:21 PM

****'s painted yo.

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave20.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave21.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave22.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/bayshave23.jpg

It's not perfect, there are some spots that just never seemed to get totally fixed through the process (looked it, till paint was on lol), some areas got a little heavy on paint, it was really tough to spray the engine bay evenly. And of course, there are some spots where stuff got in the paint because I'm painting in a trailer and not a paint booth lol.

All in all, for my first time doing any kind of body work I am pretty happy with it. :)

rocknrace03

04-20-2012, 06:46 PM

It's not perfect, there are some spots that just never seemed to get totally fixed through the process (looked it, till paint was on lol)

yeah, i worked in a body shop for 3 years and went to a vo-tech school for it and i still feel the same way, it really is art, i don't know how they do it sometimes.

but it looks great, besides, its just a engine bay, and most of the attention will be to that huge turbo :-p

PunkboySL2

04-20-2012, 07:02 PM

Can't say it looks too shaby at all. Hopefully mine turns out decent here soon.

92awdtsi

04-21-2012, 12:15 AM

looks good! i dont see any gianormus runs and your paint stuck to the surface so i'd say it came out pretty well. :mrgreen:

DPancoast

04-21-2012, 10:33 AM

Niiiiiiiiiccccceeeeee

hammtheman

04-22-2012, 03:04 PM

looks so good. cant wait to see this thing done

SovXietday

04-23-2012, 11:46 PM

yeah, i worked in a body shop for 3 years and went to a vo-tech school for it and i still feel the same way, it really is art, i don't know how they do it sometimes.

but it looks great, besides, its just a engine bay, and most of the attention will be to that huge turbo :-p

Seriously man some guys are just crazy. There were areas that I sanded, primered, it looked ehhh, so I sanded it again, came out WORSE after doing so, lol!

Thanks guys! I have one more week of classes and then finals then I'm off for a week or so before starting summer courses up. Hopefully I can get the engine in there. :mrgreen:

DPancoast

04-24-2012, 12:40 PM

Usually it comes out worse if you don't get it cleaner than before the first time you primed it haha

SovXietday

04-29-2012, 03:59 PM

Finally got a little time to work on the car, about 3 hours lol. So I started the brake tuck, can't do much more than this until I can get the car into the garage.

http://i305.photobucket.com/albums/nn212/SovXietday/braketuck1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/braketuck2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/braketuck3.jpg

Look, already drilling holes lol! This is just mock up, I have to repaint the brake booster and get a new MC reservoir.

Edit: If anyone is thinking about doing a brake tuck, give yourself time to do it nicely. It took me the full 3 hours to bend just those two lines, it's a pain but it'll come out a lot nicer if you have patience. :)

SovXietday

05-09-2012, 07:58 PM

Engine is going in within the next few days! Just need to figure out assorted hardware mostly.

ketchup!

05-09-2012, 10:10 PM

Engine is going in within the next few days! Just need to figure out assorted hardware mostly.

nice! will you be dyno or street tuning it?

SovXietday

05-09-2012, 11:51 PM

It's a ways off, but dyno mostly. Car isn't going to be on the street most likely, the fuel pump I have planned isn't designed for continuous use.

DPancoast

05-10-2012, 05:16 AM

Good stuff man. Just remember, Matt and I have a ton of Honda bolts in our bins if you get in a pinch for factory bolts

ketchup!

05-11-2012, 02:04 AM

It's a ways off, but dyno mostly. Car isn't going to be on the street most likely, the fuel pump I have planned isn't designed for continuous use.

okay. if you are interested i would like to do special kind of like documentary on your car build if you are interested?

SovXietday

05-11-2012, 04:33 PM

Sure Jimmy, what did you have in mind?

Engine is IN! Stoked to hell, but even more exhausted. What a night...

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall1.jpg

Started simple, around 7:30PM or so.

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall2.jpg

Put the twin disc on. Problem was, I don't have a clutch tool. I've eyed up clutches before, so I figured no biggy, I'll just line this **** up. 3 hours, 15 tries, and a whole lot of curse words and hammer blows later I had literally made no progress at all. None. I could not get the trans to spline onto the second clutch plate. So I did what any sane individual would do.

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall3.jpg

Yeah, I really did pull the trans apart and use the actual mainshaft as my clutch tool. To be honest, it took me under 10 minutes to get that far. I got it all back together and it slid right the heck on.

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall4.jpg

Finally!

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall5.jpg

To the bay! I have actually never used a hoist before, and I did this by myself. Only one scratch on the paint and you really can't see it. There was NO ROOM between the frame rails and the engine. Literally, maybe half an inch. Really would have been better to go up from the bottom, would have had a lot less clearance. But the problem was when I was putting the engine in it was fairly vertical, and the back of the trans was getting stuck on the subframe. To fix this, I bolted a chain onto the bottom half of the engine, pulled back to tilt the engine in, push the hoist further into the bay, AND lower/raise as needed. Finally got it to where it needed to be, annnnd the rear mount flanges were too close together to get the rear mount in. Had to pry and use a big hammer to get it in, but around 3:30AM I finally threaded the last bolt. :)

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall6.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall7.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall8.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/engineinstall9.jpg

Feels so good! Thanks to Matt for loaning me the hoist, and Dan for always having the random stuff for me if I need it lol.

Now, the fun starts. :)

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold1.jpg

DPancoast

05-11-2012, 05:52 PM

ketchup!

05-11-2012, 06:19 PM

http://vimeo.com/11363643

something like this except it would focus solely on you building your track car. Thats if you are comfortable being in front of a camera

SovXietday

05-11-2012, 11:20 PM

Yessssss

I can't believe you took the trans apart. Wish I would have asked if you had the trans mounted already when you picked up the hoist. Would have gave you the clutch tool I got with my comp stuff!

Oh well. Can't wait to see you next fab stuff!

It's ok, the B stuff wouldn't have fit anyway. Pretty much sums up how I get when I'm trying to do something that's not cooperating. :-p

http://vimeo.com/11363643

something like this except it would focus solely on you building your track car. Thats if you are comfortable being in front of a camera

Sure man, if you want to we def can.

Despite being tired, I got started on my manifold today (just can't wait, lol).

Welded the collectors up. I am running a divided setup, so it's just two 2-1 collectors next to each other. Don't mind the piping, I cleaned the weld portions, but otherwise it's getting either glass beaded or coated so it will look nice when it's done.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold3.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold2.jpg

Came out pretty nice, definitely much nicer than my last collector welds.

And lastly got the turbo in the mock-up position. May fine tune it slightly to try and get some more room for the huge 4" downpipe, but there really isn't much I can do other than tilt it just a bit more.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold4.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold6.jpg

DPancoast

05-12-2012, 08:03 AM

I just giggled like a little kid when I scrolled to the pics of the turbo. Those are the best kind of pictures

BigWhiteTodd

05-12-2012, 08:16 AM

car looks awesome and so do your welds wish I had access to a machine I have not welded in a while.

SovXietday

05-16-2012, 10:05 PM

^ Thanks dude!

Got a little further on the manifold.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold7.jpg

Mocked up one and started on two. Wasn't totally sure if I liked runner one, but it looks ok in the car. Might change it, still undecided.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold8.jpg

Quick weld. Need to bolt the exhaust housing onto the flange so that it doesn't warp when I fully weld it.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold9.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold10.jpg

And what it looks like so far in the car.

Lots more to do, the next two runners are gonna be interesting.

DPancoast

05-17-2012, 05:15 AM

Crazy. Not used to seeing the exhaust mani in the rear either. Cept on vws and mr2s.

Looks good, keep it up

rocknrace03

05-17-2012, 05:35 AM

looks awesome, can't wait til i can build a custom manifold one day! soon hopefully, where do you buy your pre-bent tubes from?

SovXietday

05-17-2012, 09:44 AM

Thanks guys!

Rockn - Manifolds are typically built with 1.5" schedule 10 "weld els". I get most of my stainless from acestainless.com, including tube and pipe (sch10).

boostedfury

05-17-2012, 11:06 AM

Awesome progress so far Aaron! And that mani looks crazy and I'm excited to see how it turns out!

SovXietday

05-21-2012, 01:44 PM

Finished it last night! 7 HOURS of welding later, lol.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold11.jpg

Runner 4 mockup.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold12.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold13.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold14.jpg

Runner 3/Final mockup. I then broke off all 4 runners, welded each individually and put it all back together and did the final welds around the collector. Was really nervous about getting into the middle of that collector when I put the last runner on, but it ended up not being too much of an issue. This is the end result.

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold15.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold16.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold17.jpg

And of course, in the car!

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold18.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold19.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold20.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/turbomanifold21.jpg

I'm pretty happy with how it came out. It's a true divided manifold, runners are all similar in length (about as equal as I can make it with space constraints and location of the turbo anyway), and it's not like anything else on the market. The only thing I need to put on now are the two Tial MVRs and the fabrication will be done. Eventually it will get bead blasted to make it look nice, but that will probably happen closer to the time that I finally start the car.

Next thing to do is figure out how to fit my massive 4" exhaust and two wastegate dumps in there, lol.

DPancoast

05-21-2012, 02:03 PM

Are you using a stock intake manifold or are you going to take a crack at your own? *cough cough*

Looks really nice man. Can't wait to see it in person

clubken

05-21-2012, 04:27 PM

absolutely awesome build! Fab work is incredible so far

SovXietday

05-21-2012, 05:26 PM

Are you using a stock intake manifold or are you going to take a crack at your own? *cough cough*

Looks really nice man. Can't wait to see it in person

Building my own. :)

absolutely awesome build! Fab work is incredible so far

Thank you sir!

DPancoast

05-21-2012, 05:46 PM

Yessssssssssssssssssssss

saxon

05-21-2012, 08:32 PM

looking good

SovXietday

05-28-2012, 09:29 PM

Got a chance to mock up the exhaust today. Really tight fit, and I was having a hell of a time cutting the material. I only have a small 10" chop saw at home, and even with a brand new blade it couldn't make a full pass through the 4" tubing lol, but this is what I managed. I have to modify the end of it a little bit, but ran out of material.

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust2.jpg

Like I said, tight fit! I would have done a better pie cut if I had a better cutting tool, but I was trying to limit the amount of cuts I had to do because of how difficult they were, especially as the blades wore down.

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust3.jpg

Made me laugh. I'm going to cut a bit off the final bend and add a straight piece so that I get a nice slash cut coming out of the hood. Next is getting the gates on and making both of the dumps, they will follow the DP out. :)

DPancoast

05-30-2012, 04:09 PM

That's gonna be awesome

92awdtsi

05-30-2012, 06:09 PM

i've seen powerstrokes with smaller exhaust.... that is awesome :mrgreen:

ketchup!

05-30-2012, 07:17 PM

good work aaron

sobigsofly

05-31-2012, 10:11 AM

where's the LIKE button at?

SovXietday

06-14-2012, 09:50 PM

Hahaha, thanks guys!

I finally finished the entire exhaust, including dump tubes. Tacked it all up, scotchbrited it, then final welded for a nice look. Wish my welds were a little nicer, I really need a belt sander at home lol.

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust4.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust6.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust7.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/exhaust8.jpg

People ask me why I am brake tucking a drag car, this is why lol!

All that is left is fitting the hood at this point. Cut the hole and slash cut the exhaust to fit nicely. Not sure if I'm going to try to get the hood cut perfect or just cut a hole to make it fit and make a CF plate to rivet around it.

Next project, intake manifold. :)

DPancoast

06-15-2012, 10:56 AM

That looks amazing man. I'm itching to see it in person

ketchup!

06-15-2012, 05:58 PM

oh boy

PunkboySL2

06-17-2012, 11:16 AM

Damn aaron that looks great.

SovXietday

06-18-2012, 09:05 PM

Thanks guys! I am working on getting the intake manifold started up here soon, I have most of the parts just trying to come up with a final design in my head first. Damn things are amazingly complicated, lol.

DPancoast

06-19-2012, 05:19 AM

Id love to hear what processes you are thinking through as you go. Nbd if not :mrgreen:

SovXietday

06-19-2012, 08:07 PM

It's really just the design process in my head. This is something like what I'm working towards.

http://www.importparts.com/product_images/h/560/004__38259_zoom.JPG

The problems are pretty obvious in that I don't have 2 cast pieces that I can weld together for the plenum. So I have to make it, and the other issue comes in the fact that I can't use standard thin wall aluminum tubing here, need to find 11 gauge 6" diameter bends, lol.

I have the runners sorted out and have individual velocity stacks for each runner. Last thing I need to is decide on my throttle body and get a weld on plate. It's not entirely difficult stuff, just need to get it all together.

Once I get injectors and whatnot I will then need to figure out how to get the fuel rail to sit nicely on top of them and look good, and all of this needs to be either sourced or made. Also debating on whether to go with 4 injectors or 8 injectors, so I will need to decide that soon as well.

Bah, lol.

92awdtsi

06-19-2012, 08:09 PM

Also debating on whether to go with 4 injectors or 8 injectors, so I will need to decide that soon as well.

Bah, lol.

why not make 8 holes and plug 4 of them up just incase you change your mind down the road?

saxon

06-19-2012, 11:16 PM

SovXietday

06-20-2012, 12:35 AM

Oh, I think I forgot to mention that I'm most likely going to be using E98 or Ignite E85. One of the two, staying away from gas, ethanol will make more power and be a hell of a lot safer than the gas will be.

So yeah, even the 2150s from FIC are going to be a stretch, especially on E98.

Spawne32

06-20-2012, 02:15 PM

Welds look great, are you going to be relocating that master cylinder? For some reason i get the feeling that you will boil over that brake fluid REAL fast with the exhaust and turbo that close.

SovXietday

06-22-2012, 01:23 AM

Welds look great, are you going to be relocating that master cylinder? For some reason i get the feeling that you will boil over that brake fluid REAL fast with the exhaust and turbo that close.

Thanks, I won't be relocating. Turbo is getting a blanket and being as it's pretty much a drag only car I'm not too worried about boiling the brake fluid. Just not enough time to heat it up with a single 1/4 mile pass at a time. No street time for this car anymore. :)

PunkboySL2

06-22-2012, 05:43 PM

^I was just going to say, should be fine. If you were really concerned you could just heat wrap the downpipe and it should be just fine.

Also just theorizing, but it seems that it may be easier to control 8 smaller injectors instead of 4 huge ones since pulsewidths can be kept bigger etc. Only thing that might be a pain is having 2 fuel rails on the same manifold, but I'm sure you could make it fit/work alright.

SovXietday

06-25-2012, 12:00 AM

Got the IM started finally. Pictars first.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold1.jpg

Runners are very short, but I don't exactly have a lot of room to work with lol.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold3.jpg

Some weld shots. The IM flange is cut from an old stock casting that I got, since getting a cnc flange is A) hard to find with injector bungs and B) silly expensive. Not aesthetically ideal, but performance wise it'll be just fine. It's getting powdercoated anyway. The weave welds are fun, hopefully they'll come out nice all the way around, it's a bit of a pain to weld in between the runners.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold4.jpg

I have decided that with what little space I have I'm going to build a true sheet metal manifold, no tubing used. I have to do some mild porting to the runners to make all of the edges meet up for a nice smooth flow, and then I'll mock up the plenum, cut the backing plate to size, and weld it all together. Hardest part is pretty much over other than some welding, so I'm pretty stoked. :)

PS, yes, I will be welding around the individual velocity stacks on the inside.

Spawne32

06-25-2012, 12:20 AM

ID injectors work fantastic for these high hp builds, and atomization is excellent even at over 2000cc

SovXietday

06-25-2012, 12:31 AM

Planning on the FIC 2150s for sure. May add a second set of smaller ones later if I need them.

The ID and FIC are both Bosch injectors and are the same actual injector, the difference is that the IDs are sold as matched sets for better idle and low speed driveability.

DPancoast

06-25-2012, 04:55 PM

Wow that's cool. Good stuff man

SovXietday

07-01-2012, 09:58 PM

Got farther on the IM.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold10.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold11.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold12.jpg

All welded up, and I started making the plenum as well. :)

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold8.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold7.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/Intakemanifold6.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold9.jpg

Beefy mofo. :P

Also picked up my Garrett 1000hp core, radiator, and my new electric water pump.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/waterpump1.jpg

That's all I got for the night, lol.

02vwgolf

07-01-2012, 10:35 PM

That IC core is beefy! Keep up the good work can't wait to see how this turns out

bmatyeah

07-02-2012, 10:41 AM

soooo stoked to see this thing getting nastier and nastier. If you need any powder coating let me know!

SovXietday

07-02-2012, 06:57 PM

Thanks guys!

Bmatt, definitely will be hitting you up. Lots of stuff getting powdercoated. :)

SovXietday

07-14-2012, 05:56 PM

Been a few weeks since I last updated I think.

Well, I did get the rest of the IM buttoned up as far as the plenum goes. Not really much as far as pictures go to show for it yet, waiting until I can get it completely finished first. I also started on getting the front end situated. I decided to get rid of the radiator support. Mostly because it was simply in the damn way of everything that I wanted to do, having nothing there frees me up to be a little bit more creative. Instead, I modded my traction bar to hold the supports for everything.

http://i305.photobucket.com/albums/nn212/SovXietday/waterpump2.jpg

Starting off, I mounted my water pump. Pretty easy, nothing fancy here.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler3.jpg

Got a piece of 1" tube, bent it up at work, then cut my ends to fit and welded it all on. Came out pretty nice. Then I mocked up my intercooler core.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler4.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler6.jpg

Fits pretty well, so all I had to do was mount it.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler7.jpg

These brackets ended up working out perfectly. Just mirrored a slightly smaller bracket on the forward tube, placed the core at the angle that I wanted it, clamped it in place, and drilled my bolt holes out. Ended up coming out really well, and it's super sturdy as well.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler8.jpg

All in all, pretty happy with how it came out. Working on getting the radiator in there as well, but I need to cut off the old endtanks and put my own on first. Nothing overly complicated. And just for fun, here's kinda a cool picture that I took late one night after I had finished what I was doing.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler9.jpg

That's all I got for now.

DPancoast

07-15-2012, 02:43 PM

Damn. That's massive!

SovXietday

08-05-2012, 05:12 PM

Sorry about the lack of updates, my summer semester is just coming to an end now so it's been pretty crazy. However, I have a few weeks off so looking to really get a lot done over the next month or so! But I did get a little bit done, finally was able to get my injectors situated and mounted.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold13.jpg

Sorry about that being blurry.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold14.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold15.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold16.jpg

Getting ready for charge pipes. :)

Accidently messed up my one fuel rail, it hit the table as I was welding and arced through. Ruined the finish, just gonna have to powdercoat them, no big.

That's all for now, hoping to get a large majority of my fab work done in the next month or so. Still need to build...

- catch can
- coolant swirl pot / overflow
- fuel cell
- intercooler endtanks
- charge piping

DPancoast

08-12-2012, 07:33 PM

Good for you man. Can't wait for the next update

SovXietday

08-16-2012, 01:01 AM

Finally got some time to work on the car again today!

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler10.jpg

Finally got my rad mounted. Pretty much had me stalled, welding it really made me hate this thing and I had a huge distaste for it for a while. It's a simple ebay cheapo rad, since the car will be running on ethanol and for 1/4 of a mile cooling really isn't going to be that difficult. So I cut the endtanks off and welded my own on for a cleaner look. Not surprisingly, the cheap-o rad uses cheap-o cores, and they were FILTHY. The welds along the core are absolutely disgusting, and it took everything I had to not just throw it in the trash and start over. A little black rad paint and the fact that it's under the rad support (actually, it basically acts as my main rad support... support lol) will be just fine though.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler11.jpg

Poor core welds aside, I was pretty damn happy about this little bracket here. Always the insignificant hard to see welds that come out nice lol.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler12.jpg

And a shot of how I installed the lower mounts. Just some 1/2" stock, drilled and tapped for 10mm bolts.

Annoyingly, mounting the rad took me nearly 2 hours, as I had to constantly take it off and put it on to make things look right. Happy with the end result though. So I started on my intercooler endtanks.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler13.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler14.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler15.jpg

I think the design is ok. Since I don't have a good way to efficiently bend the aluminum (it will usually crack and break if I bend it more than ~70 degrees since I don't have a brake here at home) I was trying to keep weld joints down and make it simple to cut. I would have liked to go all crazy and form it around and all that, but I think that would really kill any resale value that it might have so I decided to stay fairly simple. Also, since fillet weld joints need a ton of heat, I don't like to cut my holes until I have welded what I need to in. Then I cut the hole from the inside out and port to match. Comes out much nicer since the welding portion is much easier and having a nice matched port makes transitions nicer. Welds came out ok on this one, still need to work on my consistency on long runs a little bit, but overall pretty happy!

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler16.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler17.jpg

Lastly I modded my compressor housing with a cast 90 and a Vband. I've done quite a few of these cast 90s so I think I've got it down now lol. The vband to cast weld was interesting though, really all over the place!

Gonna get some more supplies tomorrow (ran out of cutting bits and need a holesaw) and then I can try and get back to it. Hopefully my throttle body showed up at work so I can start on the much more complicated cold side.

DPancoast

08-16-2012, 04:46 AM

So cool man. I love this build. Everything looks awesome

boostedfury

08-16-2012, 10:59 AM

Make me custom long tubes for my vette:) haha

SovXietday

08-19-2012, 05:55 PM

LOL Dante I could always do that, gotta have some fun stuff right?

Starting to really come together now.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler18.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler19.jpg

One side welded on and ready to go for piping! I was a little worried about welding on the core, turns out no biggy at all.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler21.jpg

The throttle body will go under the intake manifold, so it should be pretty obvious how much of a bitch this side is going to be lol.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler23.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler24.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler22.jpg

Nice short hotside run. Actually fits so well that the only way to get it in is to clock the turbo slightly or to take the intercooler off lol.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler20.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler25.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler26.jpg

All welded up! Welded pretty well, was a little iffy in spots because I don't have a way to really get the parts flush so there are some small gaps I have to work with.

And last but not least... can anyone guess where I'm going with this? Tip - it doesn't serve just one purpose.

http://i305.photobucket.com/albums/nn212/SovXietday/catchcan1-1.jpg

ketchup!

08-19-2012, 11:21 PM

dam man this looks awesome. good job bro

Spawne32

08-20-2012, 01:35 AM

holy ****in intercooler

Mishimoto

08-20-2012, 10:43 AM

Wow nice work!

jrtcbmw

08-21-2012, 11:42 AM

PAdutch

08-21-2012, 03:47 PM

This is pretty awsome... some nice fab work for sure.

Ill take a stab at the box... catch can/air intake?

JimH

08-21-2012, 05:47 PM

Awesome build and great work.

Just a little iffy on running solid piping from a vibrating engine to a solid mounted, sheet metal, intercooler. Solid mounts or not, i don't see this lasting long.

Mishimoto

08-21-2012, 05:54 PM

Awesome build and great work.

Just a little iffy on running solid piping from a vibrating engine to a solid mounted, sheet metal, intercooler. Solid mounts or not, i don't see this lasting long.

I was also curious about this.

saxon

08-21-2012, 08:16 PM

as long as he mounts the intercooler on some kind of rubber mounts he shouldnt have any problems

DPancoast

08-22-2012, 01:55 PM

Woah, that's awesome

TROLL

08-22-2012, 02:10 PM

Hey Aaron, looking awesome. I haven't had a chance to check this out lately.

What injectors did you end up going with? I think you know, I work at Fuel Injector Clinic. We match all of our injector sets and take pride in the quality of product we offer as well as our customer service. I won't turn this into an advertisement but I just wanted to make sure that you and anyone else reading this knows that Fuel Injector Clinic does flow test and match all of their injector sets. The 2150s are a sweet injector and can be run at higher fuel pressures if you need it, or of course the other option is to go with dual injectors per cylinder which you've done.

Great work again here, looking forward to seeing the project develop further.

SovXietday

08-22-2012, 05:27 PM

Aaron AMAZING work!!!

Im not gonna lie, im kinda jealous, haha your turbo and exhaust are as big as my turbo and exhaust for my powerstroke. haha.

Keep up the good work. and let me know if need a hand or anything with the build.

Jason

Thanks my man, hope everything is going well for you!

This is pretty awsome... some nice fab work for sure.

Ill take a stab at the box... catch can/air intake?

Catch can yes. Not an air intake though. Think green fluid. :-p

Awesome build and great work.

Just a little iffy on running solid piping from a vibrating engine to a solid mounted, sheet metal, intercooler. Solid mounts or not, i don't see this lasting long.

This is something I'm still a little unsure about. The intercooler does move a little bit because it's only mounted from the bottom. It's not much, but I don't think it needs much either. Still looking at some sort of insertable bushing option for the mounting points.

I could be wrong, to which something will crack and I'll just have to reweld/rethink. Won't know till I try!

Troll - I was gonna go with the 2150s but after a lot of research they weren't big enough to support my power goals on E98 or any of the new fuels. So, since I needed two sets I went with five-0 motorsports injectors since they're the only ones who make a 1600cc injector with the Bosch style injector.

SovXietday

08-25-2012, 02:13 AM

Well I got some more work done on my obnoxiously difficult box. This thing seemed so much cooler in my head, lol. Making it has been a nightmare. Because of the thin material and having to fully weld areas before I can do other ones I have been having a terrible time with warping and moving of my pieces. Also, just seemed like there would have been more room, turns out there ain't ****! Lol! Trying to get all of this stuff to fit, with fittings, and look good has been a huge challenge.

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank2.jpg

This is the swirl pot box. 16AN in and out. This was the only place I could put them, it looks kinda funny in the picture but it looks just fine in the car.

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank3.jpg

Welding schtuff.

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank4.jpg

Complicated ass underbelly of the beast. Problem is, it can't just be a box, rather it has to fit around the shock tower bumpouts.

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank6.jpg

Dear JEGS, wtf rad cap is this? Oh well, at least it welded nice lol.

And of course, catch can fittings placed on.

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank7.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank8.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank9.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank10.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank11.jpg

Still have to figure out catch can filter placement, but I have a few ideas. Just need to find filters first. Also need to box in the rest of the catch can on the back. Should be an absolute blast. /sarcasm.

Since there was so much warping and having to chase weird piece seperation issues (was having parts separate as I was welding, never seen this before?) I also get to apply a few bondo skim coats and sand, yaaaay lol

justinlansdale

08-25-2012, 10:45 AM

this thing is ****ing wicked. awesome progress, aaron!

rocknrace03

08-25-2012, 12:19 PM

sheet metal is rough to weld. i have personally never welded aluminum but i would guess that like steel you need to move around alot to keep the area from getting heat soaked. you can really distort stuff by welding a single bead across thin metals. but awesome fabwork aaron. im looking to find something that i can do this sort of thing on too! keep up the good work!

biggard09

08-27-2012, 08:06 AM

Car is really coming along.. Wish I had some of your skills.. This thing is gonna be a killer once its out.

cmr076

08-27-2012, 09:47 AM

SovXietday

09-07-2012, 11:46 PM

this thing is ****ing wicked. awesome progress, aaron!

Thanks brotha! Haven't seen you in forever!

sheet metal is rough to weld. i have personally never welded aluminum but i would guess that like steel you need to move around alot to keep the area from getting heat soaked. you can really distort stuff by welding a single bead across thin metals. but awesome fabwork aaron. im looking to find something that i can do this sort of thing on too! keep up the good work!

Thanks bud, you have a PM!

SovXietday

09-11-2012, 11:41 PM

Ok, this is going to be a big ass update, so bear with me. I just sifted through like 60some pictures lol.

I have officially finished all of the real fabrication in the engine bay! There are still a few minor things to finish up, but as far as big parts go there I'm all done! Pretty excited, and definitely very happy with the way things have come out.

Still have to make fuel, vacuum, brake, and clutch lines. This shouldn't be a huge deal, just time consuming since it will all be hardline (or as much as possible). Couple of brackets here and there, and I still have to cut out and port my wastegate holes on my manifold lol. Can't forget to do that, or things will get interesting rather quick. :P

First things first, finished my catch/surge/overflow tank!

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank12.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank13.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank14.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank15.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank16.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/catchsurgetank17.jpg

I'm sure some of you are thinking about the filter hanging over the front tire. Don't worry, I'm going to build a sheet metal shield that will divert any blowout oil down under the frame rail and away from the tire. With only the small holes that are drilled I shouldn't really have an issue with it blowing out significant amounts of oil, but just need to take the precaution just in case. Better safe than in the wall at 140+ because I oiled the driver tire! As for why I put it there, honestly... only place I could make them both fit! The space was larger in my head, always is lol.

FINALLY got my throttle body. It is a 75mm, which is ~3" (same size as my IC piping). So I was able to finish welding the cold side piping up.

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold17.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold18.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold19.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intakemanifold20.jpg

Need a bigger welder, I was REALLY pushing the little 165 to make that flange weld with the TB bolted onto it. Would have welded better without the huge heat sink but I didn't want it to warp.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler27.jpg

Quick weld picture, this is the mating flange to go on the throttle body.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler28.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler29.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler30.jpg

Cold side tank ready to go on. It's basically the hot side just inverted. Unfortunately with basic hand tools its extremely difficult to get complex designs and keep the number of welds down. I can't even come close to bending 1/8th sheet here at home, trust me, I've tried. So fairly simple, but still trying to promote the air to flow down across the center of the IC so it covers more surface area. Also... just kind of happens to work well with trying to get back up to the TB lol.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler31.jpg

This was such a PITA to get lined up right. Also backed myself into a corner with the middle weld on the IC piping. Came out really ****ty but you can't see it so it'll be ok.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler32.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler33.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler34.jpg

Putting another Vband on was impractical and very difficult with the tight bends. This should work just fine. I am going to allow the intercooler to "float" on pins, so that the engine is able to move it around a little bit. Hoping that allowing just a little bit of movement will keep me from tearing the vbands apart. If not, oh well, I'll put some vanjen clamps in and call it a day.

Finally, the finished product.

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler35.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler36.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler37.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler38.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler39.jpg

And of course, bumper fitment!

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler40.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/intercooler41.jpg

Next is the fuel cell. :)

DPancoast

09-12-2012, 05:36 AM

As usual I'm trying to think of something to say....

Lol

Awesome job man. I wish I could watch this go down in person. So much good stuff going on.

Mishimoto

09-12-2012, 10:19 AM

That catch/surge/overflow tank is super impressive! Nice work.

Dominick

09-12-2012, 11:04 AM

Just saw this build. HOLY ****! SO NICE! HONDA LOVE!

BigWhiteTodd

09-12-2012, 06:25 PM

That all looks like amazing work I cant wait to see some track times.

cmr076

09-12-2012, 08:52 PM

Great job as always, if you ever want to switch professions let me know! We are always looking for talented welders/fabricators

SovXietday

10-23-2012, 04:36 PM

^ Thanks guys!

Got a bit inspired to work on the car and do some stuff that needed to get done. So here we go.

Put the slicks on. Needed to use the front wheels briefly for my other car so I could get to school (seriously who blows two tires in a week?).

http://i305.photobucket.com/albums/nn212/SovXietday/hood1.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/hood2.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/hood3.jpg

I've had these for a while now, just never used them. Will probably change the color and I need to find myself a set of cheap skinnies somewhere as well.

Finally got to the part I was dreading, cutting the hole into my Seibon hood. I'm rather partial to this hood after how much BS I had to go through to get it 5 years ago (got one, hit a deer, trashed it, ordered replacement, UPS damaged it, company never sent me a replacement, had to file CC dispute and order another one from another car, all while this car was my DD!). But, gotta do what you gotta do right?

http://i305.photobucket.com/albums/nn212/SovXietday/hood4.jpg

Whew.

http://i305.photobucket.com/albums/nn212/SovXietday/hood5.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/hood6.jpg

http://i305.photobucket.com/albums/nn212/SovXietday/hood7.jpg

Think it ended up pretty nice. In all honesty I really wanted the exhaust to be just a tiny bit higher, about a 1/4" above the hood but after I cut it and got the ends beveled flat it ended up being pretty much dead flush, but that's just me being picky lol.

Finally, I drew up a bunch of versions for an exhaust plate using Solidworks and came up with this. Checked it with a 1:1 scaled printed version and it's perfect. There is also an underside piece that has matching bolt holes. Essentially it will sandwhich the carbon in between in conjunction with some double sided tape to stay put.

http://i305.photobucket.com/albums/nn212/SovXietday/hood8.jpg

So, just waiting to get a price and I'll get it cut!

All I got for now, still trying to find the motivation to take my old gas tank out and start on my fuel cell. This kind of work is much more fun when you don't have to lay on the ground amongst wolf spiders, lol.