Big Single Build

[Boost4VR4]

Before I get the haters in here asking me why, I want to put a few things out here so I can clear things up.

1. The car is paid off and I have 2.5 times more than I paid into the car just in preventive maintenance.
2. I am not super duper concerned about blowing anything up because I don't have a lot into the car overall.

Now that those things are out of the way, here's some background on the car:

The car is a 93 Dodge Stealth Base SOHC. Most of the people that attended NG, saw it run the autocross and the drags. The Drags were pathetic, but hey, it was fun. The autocross was quite fun and I thought the car held it's own despite being low on power.

Here's the issues I am facing now:
The car is eating injectors, on the way home from NG, about 10 miles south of Toledo, 2 injectors decided it was time to let go. So I am getting fed up with trying to track down SOHC injectors (yes they are different) I am converting my plenum to a DOHC plenum as well as the lower intake manifold to a DOHC lower intake manifold. I was doing some searching and found that the 3.5L Diamante intake plenum is driver's side throttle, so that makes my piping much easier to run for the turbo. I also have a set of NA injectors made for the DOHC which I am going to hopefully install when I get the manifolds switched out.

The turbo I am eyeing is a Garrett 55 trim. It is vband and externally gated. I am looking for a fabricator to make the exhaust manifolds, but I may have a source.

I need to look at injectors, resistors, fuel pump, and flashable 99 ECU and convert it to OBD1.

I will keep you guys updated!

Edit: I found my manifold that will work... The avenger 2.5L V6 SOHC intake plenum looks the same as the NA plenum except throttle body mounts on the driver's side. I was going to go with the Spirit/Shadow/Caravan manifold, but then I would need to replace the lower intake manifold with a Spirit/Shadow/Caravan manifold because of the runners.

[Amphiron]

I won't hate but please don't replace your transmission with another NA 5 speed. You should be able to find some manifolds on ebay pretty cheap.

[stealthee]

No SOHC injectors are not different. Its year stuff that is different. I have DOHC injectors in my SOHC and they popped right in.

If I recall a DOHC intake mani doesn't line up with a SOHC intake mani.

EDIT:

DOHC intake mani definitely will NOT work on a SOHC. DOHC lower intake is different because of intake ports on SOHC heads. DOHC upper intake won't bolt to SOHC lower intake due to difference in port design.

SOHC intake gaskets
http://www.rockauto.com/getimage/getimage.php?imagekey=125436&imageurl=http%3A//www.rockauto.com/info/Fel-Pro/MS93795-3_TOP.jpg

DOHC intake gaskets
http://www.rockauto.com/getimage/getimage.php?imageurl=http%3A%2F%2Fwww.rockauto.co m%2Finfo%2FFel-Pro%2FMS94946_TOP.jpg&imagekey=125598-0&width=450

[Amphiron]

Well Kevin, if you want you can buy my heads. Too bad you didn't post that like 2 hours before.
Actually maybe I don't know here is another set from another MFG for SOHC gaskets
http://www.rockauto.com/getimage/getimage.php?imagekey=1814934&imageurl=http%3A//www.rockauto.com/info/RockProducts/IG125.jpg

[stealthee]

You can't even use DOHC heads on a SOHC block. SOHC doesn't have the proper mounting points for the DOHC timing set up.

[Nationalmilkman]

I'm in for the details on this and hope it works out well for you bud.

[Boost4VR4]

If you flip over the SOHC gaskets you can see they line up, the ports are off a bit though... I will have to cotemplate this issue... I think it could be made to work if I install a metal spacer that has the port differences milled out on the top and the bottom. My biggest concern is finding an intake plenum that is driver's side that bolts up to the lower intake manifold.

[anyonebutme]

Use the manifold from the shadow/spirit, can be flipped either way.

[arm0red1]

Well, I was just going to say TT swap it with dohc heads and boost built bottom end, then you can use an avenger/sebring/stratus intake off the v6 (6g73 engine)- but that may be cheapening the experience of your build.

also for a tranny, swap to the fwd auto, may not be as fun, but has been proven over and over to handle 550-600 fwhp with an oil cooler. sadly the fwd 5 speeds are weak.

heres the intake setup off my own single setup when it was being fabbed, but its for a 6g72tt dohc:

http://i1246.photobucket.com/albums/gg617/arm0red1/IMAG0431-2.jpg?t=1339889937

http://i1246.photobucket.com/albums/gg617/arm0red1/IMAG0231.jpg?t=1339531229

http://i1246.photobucket.com/albums/gg617/arm0red1/IMAG0232.jpg?t=1339531291

[Nationalmilkman]

Those auto trans cars are FAST!!

[Boost4VR4]

I am sticking with 5 speed until I break my 5 speed.

[whitedragon]

I'm hatin!

You so crazy!

[Boost4VR4]

I'm hatin!

You so crazy!

You would!

I am in the planning stages at this point.

[arm0red1]

kay, but lean more towards breaking it, and have a standby on hand when it does, as its a known failing point. Outside of that, goodluck! Can't wait to see your build/dyno results- keep us posted- and my avenger manifold fits like a glove btw, some have issues with emissions on the bottom, but when a few tabs are ground down, its perfect.


with the drivers side tb, I'm not sure if your master cylinder is in the same spot as a regular tt, BUUUUUUUUUUUUUUUUUUT, heres another helpful tip for some possible design forsight

for the brake reservoir on top of the master cylinder- it will give you problems routing intercooler piping to that side of the engine bay, for clearance I actually used a remote mount reservoir off a dsm, they have barbed plugs that go into the cylinder, also if yours is like mine, you will have issues with the hardline on the end of the cylinder. I bought the abs delete from stm as an excuse for weight reduction, but honestly you can get away with having just one braided line made with a banjo fitting/bolt to go on the end of the cylinder- that gave me enough clearance for my 90 reducer elbow coupler from 3" to 2.75" as the tb points pretty much straight at the master cylinder. The other ways to get around this are to

A) weld the tb flange at an angle to bypass the mastercylinder

B) make an adapter tube that bolts onto the flange for the avenger and for our tb on the other end and to route our tb farther down- but that means more gaskets/more places to possibly leak.


heres pics of how i handled the brake reservoir on mine

you can see the edge of the tb in the pic, and how i used the flatter banjo fittings and the remote mount barbs/reservoir off a donor dsm for clearance as my 3000gt tb flange was litearally just welded to the plenum after the avenger flange was cut off.


http://i1246.photobucket.com/albums/gg617/arm0red1/IMAG0221.jpg?t=1339531121


also for manifolds, you could make some from a fabricator, or you can do these!

equal length, 304ss, hug the block and CHEAP!

they're 350z headers from ebay and inspected, mounted to 3000gt exhaust flanges from IPS motorsports- the runners linup dead on, you just need to weld them together

http://i1246.photobucket.com/albums/gg617/arm0red1/IMAG0165-1.jpg?t=1340683132


here you can see how they look in an engine bay mounted, pretty snug, and they're pretty ideal for anything mounted sideways off the block, like a single turbo.

http://i1246.photobucket.com/albums/gg617/arm0red1/IMAG0184.jpg?t=1339531318


hope this helps you to hash some ideas, I know these are the kind of things I wish someone told me when I got started on this, they would've made this go a LOT faster haha

[Boost4VR4]

I wont have many issues with the fitment of stuff, I have quite a bit of room to work with compared to DOHC engines. The only issue for me is the distributor is located where the TB would be and the brake master like you mentioned... That part needs some ironing out... I think if I route my piping down before the brake booster and then across to a FMIC core. The throttle cable would come straight out of the firewall and directly into the throttle body, I can get it to clear the everything OK. I would keep A/C and delete ABS.

Also the turbo is going to sit in a different location that everyone may think... It will be sitting in front of the large rad fan. I would switch the fan positions. I think I would remote mount the IAC in this setup.

[Amphiron]

Those auto trans cars are FAST!!

Really making me wish my car would have worked out and I could have added a turbo. There really is so much you can do the auto trans these have thanks to the DSM crowd.

[Nationalmilkman]

FYI - Base/ES Stealths have no ABS.

[stealthee]

Some ES did have ABS, but not base that I have ever seen have ABS.

[arm0red1]

fyi, abs was only a thing to ditch off my car, and doing the 1 line gave me an excuse to get the abs delete. in his case, he can just replace the one line, the reservoir and go on living.

[Boost4VR4]

I pulled the ABS fuse, it most definitely has ABS it's a fully loaded base model.

Car is down until I fix it again, gotta love tensioner pullies flying off the car... Got a replacement pulley and new serpentine belts.

I picked up a 6G73 intake to try and toy with and see what I can make of it. I may keep the existing plenum, but just route the IC piping along the firewall. The reason I picked the 6G73 plenum is because it has a driver's side throttle body which is only to simplifiy my IC piping. This will most certainly require a custom fabrication to get to mount to the lower intake manifold. I am thinking of designing a special adapter plate to mount the 6G72 DOHC/6G73 intake plenum to the lower intake manifold on a SOHC. I think it can be achieved, it will be a decent amount of fabrication.

[MeTarzan]

This will most certainly require a custom fabrication to get to mount to the lower intake manifold. I am thinking of designing a special adapter plate to mount the 6G72 DOHC/6G73 intake plenum to the lower intake manifold on a SOHC. I think it can be achieved, it will be a decent amount of fabrication.

Hey man if you want a flange made it wouldnt be that hard. We could make a 1/2" spacer out of some 6065 aluminum and have the ports 3d contored so it would be a smooth transition like our port matched exhaust flange in the picture
https://sphotos.xx.fbcdn.net/hphotos-ash4/406976_247770001962484_650567348_n.jpg

[Boost4VR4]

Hey man if you want a flange made it wouldnt be that hard. We could make a 1/2" spacer out of some 6065 aluminum and have the ports 3d contored so it would be a smooth transition like our port matched exhaust flange in the picture
https://sphotos.xx.fbcdn.net/hphotos-ash4/406976_247770001962484_650567348_n.jpg

That's what I am working on, here's one side of the model:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/AdapterPlateSOHCLIMside.jpg

[MeTarzan]

it would be very simple...

[Boost4VR4]

it would be very simple...

Here's the issue I need to sort out tarzan. The 6G73 plenum needs to do 3 things: Clear the distributor, clear the hood, and bolt on to the LIM on the SOHC.

The 6G73 plenum has the exact same mounting points as the 6G72 DOHC plenum, I don't have that issue if I had a DOHC car. If you see the first page of posts, I need the 6G72/3 ports to taper in to the SOHC ports on the LIM. And since the mounting points on the SOHC LIM and the DOHC LIM are different, the adapter plate needs to bolt down to the SOHC LIM then the plenum can bolt down on the adapter plate. The adapter plate needs to bring the plenum up about 1-1.5 inches to allow the 6G73 plenum to clear the distributor cap.

[Amphiron]

If I am understanding this correctly the problems the adapter has to accommodate are
1. The ports do not line up flush
2. The mounting locations of the lower intake does not line up with the 2.5l plenum
To accomplish this; first the adapter is going to have to have tapered ports so that the flow from the lower intake to the plenum is flush.
Second the adapter is going have to mount to the lower intake and the mounting bolts will sit flush on top of the adapter so that the plenum can mount to it. I suggest doing this by using flat head socket cap bolts and counter sinking the holes 45 degree so that they will sit flush and with a bit of RTV around the cap will be 100% sealed before the gasket even goes on.
Third the adapter plate will have to be drilled and tapped for the mounting of the upper intake. Since the upper intake is a bit heavy use some thicker studs. To make it easier to service when the time comes make sure you get studs that have a allen socket in the top or a hex head. You could also use press in studs and press them in from the bottom side of the adapter. That would be the strongest way to do it.
Forth you need to get a set of calipers and start taking measurements on the ports of the lower intake and the upper intake so that we I can start making a CAD design that can be transferred right to a CNC mill and set loose.

[Boost4VR4]

It's even easier if I use the SOHC and the DOHC gaskets and lay them on a sheet of plywood and cut it and match it with plywood then take the model to a CNC mill and have it cut.

[Amphiron]

That's not even going to be close to accurate enough if you want to all to fit together like OEM. You need precision measuring tools if you want to provide something a machinist can use. I'm sorry but if I bring a piece of ply wood into work I will get laughed at. I'm also not sure how we are going to cut the tapered hole, usually that stuff is cast from a dye. It might even have to be done on a older mill at work where you can set the angle of the head. You are gonna need a good print with a section view etc.

[Amphiron]

here is a quick 10min mock up i did in sketch up, i would have used a better cad program but I don't have any dimensions and sketchup is good for doing guess work, which is what this is.
http://i24.photobucket.com/albums/c41/AMPHIRON/quickquick.png

[anyonebutme]

That's not even going to be close to accurate enough if you want to all to fit together like OEM. You need precision measuring tools if you want to provide something a machinist can use. I'm sorry but if I bring a piece of ply wood into work I will get laughed at. I'm also not sure how we are going to cut the tapered hole, usually that stuff is cast from a dye. It might even have to be done on a older mill at work where you can set the angle of the head. You are gonna need a good print with a section view etc.

ball mill.

[Amphiron]

We don't have a ball mill lol. I was thinking about using our Cincinnati horizontal boring mill. I think if I used the right diameter cutter and then rotated the table to the correct angle and cut one side of each port, tilted the table to the to the other dimension cut the other sides of the port and then mill out the centers that would leave me with the correct taper. With the taper like that I don't think its going to be easily zipped out on a 3 axis CNC mill, you would need a 5 axis for something like this.

[MeTarzan]

Well I guess this is much better view of the flange you can see the contour into the LIM ports better.

we have a HAAS VF2 mill that we do our work on here at the shop

[Boost4VR4]

That's not even going to be close to accurate enough if you want to all to fit together like OEM. You need precision measuring tools if you want to provide something a machinist can use. I'm sorry but if I bring a piece of ply wood into work I will get laughed at. I'm also not sure how we are going to cut the tapered hole, usually that stuff is cast from a dye. It might even have to be done on a older mill at work where you can set the angle of the head. You are gonna need a good print with a section view etc.

The reason why I thought to start with the plywood is because you can have it traced on an aluminum block and the piece can be cut free-form which is what I am thinking you're going to need to do since this piece is so complex.

[MeTarzan]

you have a PM Boost

[Boost4VR4]

I may take a different approach to this intake issue, I can use the existing intake and go water/air IC and probably spend less money on the intercooling setup...

[Boost4VR4]

Picking up a 2nd SOHC engine to build on.

Here's the updated parts list:
https://docs.google.com/spreadsheet/ccc?key=0AjTFGHBt7Nw-dFF2WFBqRGhZTWlscGllNndrbnU1bGc#gid=0

[Boost4VR4]

Revival of this project starts today!

Picked up used SOHC engine. Tonight I will pull it out of the truck and put it on an engine stand and start the teardown!

Since I have an engine in the stealth already, in the coming months, I will be able to fabricate everything on that car with the engine in place. The list hasn't been updated yet, but I will be going through it again and making adjustments. Pictures will be in order very soon.

[Boost4VR4]

Oh... there is a few more things up my sleeve in terms of this build...

I think I am going to build a single connector engine harness and relocate the main fuse box in the car.

The following items will get deleted:
A/C
Evap and EGR
Interior

So here we go with the real stuff. I picked up an engine from Josh Mitoska from 3000GT/Stealth Supply. I didn't get an NA engine, I picked up a SOHC engine. This is a SOHC turbo build, so all the haters and naysayers and people questioning this build, keep the comments to yourselves. I haven't torn down an engine before, so this will be both a first and a new learning experience. I have been fortunate enough to have only worked on engines from the heads up.

So I got to work on this engine. The engine was pulled from a car that was a parts car and the engine had a blown head gasket. Honestly while tearing this engine down as far as I did, most of the components are in good shape. So here's what we have to start with:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-15.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-15.jpg.html)

Off comes the Throttle body:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-16.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-16.jpg.html)
IAC and TPS pulled injectors are not for this car, they are for a Jaguar XJR:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17.jpg.html)
Components off the back of the intake plenum:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18.jpg.html)
Plenum Pulled:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-19.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-19.jpg.html)
Lower Intake Plenum pulled. All of the LIM head studs were bent causing a lot of grief during the removal process:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20.jpg.html)
Pulled the rear valve cover off to basically check condition of everything, seems to be in working order. Rotated the crank a few times and the valves visibly move normally:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21.jpg.html)
Pulled the timing belt off and worked on removing the water pump, got stuck on an issue removing the upper timing back covers, so will need to remove cam gears to gain clearance around cam sprockets to bolts behind cams, namely on the rear cam:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22.jpg.html)
It also looks like the oil pump seal blew at some point because it's quite dirty.
All the stuff I removed:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23.jpg.html)

[DocWalt]

Good progress so far :)

[Boost4VR4]

Alright, made some more progress tonight. So the goal was the pull the heads, and that is what I did:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-1.jpg.html)
Here's where the low compression issue was:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-1.jpg.html)
For the most part, everything looks good, cylinder walls are smooth.a

[Boost4VR4]

OK ladies and gentlemen, I want to put a status update out there because there will be quite a bit of insanity going on with the car.

Keep in mind with all of the work going in to this project it really is not all in vain. While I really want to be unique and attempt to get a single turbo setup bolted on a SOHC engine and go fast, it really is not about that. I want to build something that is challenging. After all, I really don't have a ton of money tied up in this car, and the existing engine in the car still runs fine. There are many reasons why I didn't pull the engine out of the car and rebuild it, but I won't list them here. Thanks to Josh Mitoska for pulling this engine last minute before the NG and for giving me a killer deal on the entire engine.

So here's what I am after with this car. I have always liked what NRE does with their engines in terms of the harnesses they build. They build single connector harnesses, so, one of the things that I do plan on doing is to build a single connector engine harness that disconnects near the firewall. One of the reasons I want to do this is to clean up some of the wiring that gets routed every which way across the engine. Also I really dislike having to disconnect all of the plugs off of the main harness just to yank the engine out; it would be much simpler to unplug one plug and yank the engine out with all of the components still plugged in.

I also never liked the idea of the main fuse box under the hood of the car. I mean I get why it's done, but I would much rather have it relocated inside the car. So that will be taking place as well, this will be a major undertaking as the main fuse box wiring is kinda a cluster.

Also, since I am really turning this into because racecar status, the interior panels will be coming out. The door locks and power window switches will be relocated to new switch panels in a modified center console and the center console will also be fitted with switches for manual override to any components that are powered by a relay. My thought is to retain existing relays, however install switches that allow me to manually override the relay in the event a relay goes bad or other issues exhibit their ugly head. The interior lighting will go away, the unnecessary electronics will go away, ABS will be deleted, A/C will be deleted, all of the carpc stuff that I originally planned for the car will be put in a different vehicle.

So what are the plans for the engine?

Well for starters:
Bored .030 over
Beehive Valve Springs
Wiseco Forged Pistons
Ninja Performance Chromoly Connecting rods and wrist pins, rings
Webcam 272 cams
1000CC Injectors
Air to Water Intercooler setup with external heat exchanger, pump, icebox, piping
Custom VBand intake piping
Borg Warner Twin Scroll Divided T4 Flange VBand Exhaust and compressor side< This turbocharger is MORE than sufficient for this engine.
Oil Cooler and lines

For now, that is the sneak peak in terms of the build. More to follow.

[Boost4VR4]

OK ladies and gentlemen, I want to put a status update out there because there will be quite a bit of insanity going on with the car.

Keep in mind with all of the work going in to this project it really is not all in vain. While I really want to be unique and attempt to get a single turbo setup bolted on a SOHC engine and go fast, it really is not about that. I want to build something that is challenging. After all, I really don't have a ton of money tied up in this car, and the existing engine in the car still runs fine. There are many reasons why I didn't pull the engine out of the car and rebuild it, but I won't list them here. Thanks to Josh Mitoska for pulling this engine last minute before the NG and for giving me a killer deal on the entire engine.

So here's what I am after with this car. I have always liked what NRE does with their engines in terms of the harnesses they build. They build single connector harnesses, so, one of the things that I do plan on doing is to build a single connector engine harness that disconnects near the firewall. One of the reasons I want to do this is to clean up some of the wiring that gets routed every which way across the engine. Also I really dislike having to disconnect all of the plugs off of the main harness just to yank the engine out; it would be much simpler to unplug one plug and yank the engine out with all of the components still plugged in.

I also never liked the idea of the main fuse box under the hood of the car. I mean I get why it's done, but I would much rather have it relocated inside the car. So that will be taking place as well, this will be a major undertaking as the main fuse box wiring is kinda a cluster.

Also, since I am really turning this into because racecar status, the interior panels will be coming out. The door locks and power window switches will be relocated to new switch panels in a modified center console and the center console will also be fitted with switches for manual override to any components that are powered by a relay. My thought is to retain existing relays, however install switches that allow me to manually override the relay in the event a relay goes bad or other issues exhibit their ugly head. The interior lighting will go away, the unnecessary electronics will go away, ABS will be deleted, A/C will be deleted, all of the carpc stuff that I originally planned for the car will be put in a different vehicle.

So what are the plans for the engine?

[DocWalt]

Where does the CarPC end up?

[Boost4VR4]

Where does the CarPC end up?
I am not sure yet. I know for certain that the amplifier that I was going to use for the audio setup will be going in my mom's Jaguar. She wants to upgrade the sound and out of the factory they put the battery in the trunk, so it should be an easy hookup.

[Boost4VR4]

Alright, a lot of things have happened this week, but i did find time to work on the engine. So I started more teardown, I got the torque convertor off of the flexplate and took the flexplate off. Got the engine on the stand and started cleaning up the parts and organized parts. Tomorrow I need to go through and throw some bolts in bags and such. So I cleaned parts and then I started to work on the bottom end. So I took the oil filter housing off, took the oil dipstick tube out, rotated the block and drained the coolant. Unbolted the oil pan off voila:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-2.jpg.html)
Talk about SLUGDGE! The engine did sit for awhile, but I also think before the head gasket blew that this engine had poor oil change routines and the pickup tube is full of sludge. So basic design, 2 bolt mains. Took the girdle off and took a photo of each of the bearings:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-16-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-16-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-15-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-15-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-2.jpg.html)
Here are some shots of the main crankshaft journals:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-2.jpg.html)
I loosened the connecting rod bolts and will be pulling the pistons out and sending the block out to a shop to be built.

[Boost4VR4]

So I got a bit accomplished today. Pulled the pistons out, pulled the crankshaft out. Super clean bottom end other than the sludge at first.
Here are the results:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-18-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-26.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-26.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-29.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-29.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-30.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-30.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-31.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-31.jpg.html)

[DocWalt]

The bearings all look pretty good, but man, talk about sludge!

[TwIzTeD_3kGt]

Looks like a Saab I once owned, they're known for poor oil change maintenance causing exactly that. Sludge.

[j2k4]

I'm always amazed to see decent bearings on a sludge-pump.

Looking good, Kev. :)

[Chris@Rvengeperformance]

nice, if that was a TT with that sludge there would be rods through the block.

[stealthee]

SOHC's definitely can take a beating.

[Boost4VR4]

So part of the project is to really lighten the car as much as possible and turn it into a tin can racecar basically... Except 3/Ses are pretty sturdy and stout cars so here's the accomplishment of this past weekend in 90 degree heat:


http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/Because%20Racecar/temporary-13.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/Because%20Racecar/temporary-13.jpg.html)

[Boost4VR4]

Pistons ordered. Should be here in 4-6 weeks.

[Boost4VR4]

Prosport 60mm gauges ordered. I ordered wideband O2, oil pressure, oil temperature, fuel pressure, water temperature, exhaust gas temperature, boost/vacuum.

[Boost4VR4]

Ok, got a new tool to add to the stable. I picked up a small portable brake press tool for bending sheet metal. Since I need to fabricate the center console I figured I would get the tool to make it the easiest, so here we go.

Building out the center console. The design is simple. I want to use some of the bolt hardware that originally was used to some sections that bolt to the stock bars and such. It appears only a handful of bolts will be needed. I am building the center console out keeping in mind to provide the shortest path for the driver's hand to touch all of the panel buttons, switches, and to view the gauges. I am not adding any of the gauges to a pod on the a-pillar. I feel that the a-pillar should be free and clear of all obstructions, so all of the gauges will go in the center console. Also I will be building the center console in to two pieces. THe goal is to wrap around with the single sheet I have, then I am adding another sheet on top of the side facing the passenger seat that will be where all of the wiring will be.

Pics to follow....

[Boost4VR4]

And gauges arrived, Monday I picked up New in the box Brian Crower 264/264 .390 lift SOHC cams for a GREAT deal on the other forum. Those are arriving tomorrow. Next on the list is measuring the valve springs and getting new titanium valve springs and retainers. Wiseco should be calling any day now to let me know they are ready to ship the pistons out. Once those ship, it's smooth sailing with the rest of the stuff. I still need to get the whole intercooler setup ordered someday... and the turbo...

[HilbillyHomeboy]

Are those the old or new BC cams?

Jeremy

[Boost4VR4]

They are the SOHC cams, what issues could I potentially run into? I would say that they are most likely the BC cams prior to these revisions everyone has been talking about.

[j2k4]

Cams have issues - gotta make the issues go away.

People have run them without issue, yes?

Where'd the idea for the cams come from, Kev - if you don't mind my asking?

[vroom4]

Same place as the idea for the built SOHC haha.

[Boost4VR4]

Cams have issues - gotta make the issues go away.

People have run them without issue, yes?

Where'd the idea for the cams come from, Kev - if you don't mind my asking?

The cams provide a pretty decent horsepower upgrade on the SOHC as a base upgrade. I figured while upgrading everything and adding a turbo and all of that jazz, but not doing anything to the heads or going with oversized valves, I figured that this would be a fairly inexpensive path. The cams only cost me 145 shipped, so I think for that price, these will definitely be an added bonus for the setup.

Just to quell your fears, these cams were originally purchased by the previous owner on 06/28/2013 so I am thinking these have probably been revised.

[Boost4VR4]

Same place as the idea for the built SOHC haha.

Everyone has a passion here with their 3/S. Mine is simply doing something that hasn't been done often.

But doing it RIGHT. I sincerely hope that there is a genuine appreciation for going down the path of doing it right versus throwing a junkyard motor in and patching it together to work. I'm not doing a junkyard motor strap a turbo on and call it good. Building out the block correctly and doing a full rebuild on the engine, having the crank balanced for the connecting rods and lighter pistons, etc. Having it done right. I want a reliable turbo car that I can race around on the track without doing a lot of monkeying around with a bunch of tunes or changing everything out all the time. I have a power goal of double it's current horsepower rating. If I can conservatively get a little more out of it, awesome. If I don't, I can say that I have pursued something very little have but more importantly, if the setup is reliable and not much needs to be changed or tuned, I am totally OK with double the horsepower goals. It's about having fun with the car, it's not necessary to be the most powerful car out there.

[beepbeep]

Subscribed.

[Boost4VR4]

Wiseco custom forged pistons shipped this morning, should see them next week.

[Boost4VR4]

Everyone really cares about pictures, so here are the camshafts and gauges:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-5.jpg.html)

[DocWalt]

SOHC cams are so thick. Gauges look good, the analog wideband should be really nice as long as it can sweep fast enough.

[Boost4VR4]

SOHC cams are so thick. Gauges look good, the analog wideband should be really nice as long as it can sweep fast enough.

It is a pretty nice wideband to be honest. It should be able to sweep pretty quick. As long as the fuel maps are setup correctly, it shouldn't need to sweep a lot. I honestly am not really worried about changing the valve springs at this point because the springs are so beefy. The springs can really withstand a high load and I doubt they will float.

[CoopKill]

Done yet? :suspect:

[Boost4VR4]

Moar pics to add! Pistons showed up:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-5.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-6.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-6.jpg.html)

[wingnut]

Done yet? :suspect:

lol...as if you have a lock on "most efficient rebuild ever" http://i266.photobucket.com/albums/ii269/theogrit/bth_1sm187sneak.gif

[Boost4VR4]

So I got my new custom collector's plates ordered. Plates will say "STOHC"

[Boost4VR4]

So I made some progress. I cannot stress the importance of having the correct tools for the job... I was having difficulties with this cheapo valve spring compressor, and spent like 1 hour to get one valve spring off. So I said forget this tool and went and got an actual nice valve spring compressor tool, 20 minutes later, had all of the valves out and sorted.

So I made some interesting revelations. The intake valve and exhaust valve are different sizes, but, the intake valve is double the size of the exhaust valve. Not sure why people are thinking these heads don't flow... But whatever. So the other thing I want to point out to is that the cylinder areas on the heads have an oblong milled out area where the stock pistons, with their oblong cut out on the surface, meet. What does this mean? While I may have deep valve reliefs in the new pistons, I need to have the heads milled out a bit to accomodate the increased piston surface area, or I am going to have higher compression ratio than stock and I am also going to have flow issues. So now that the valves are out of the heads and the heads are ready to go with the block for machining, the project is at a halt for a bit.

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-8.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-8.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-7.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-7.jpg.html)

[sketch]

are you done yet.

[Boost4VR4]

are you done yet.

I hope the have the engine and heads out to the machinist this weekend to get work done!

Then I have to push a big order through for rebuild stuff, I am picking up the main and rod bearings tonight so I can drop the crankshaft back in the block and so the machinist can have the crank turned and balanced for the new pistons/stock connecting rods.

[Boost4VR4]

Well I haven't received a response from the machinist as to when I can drop off the engine so I have proceeded with ordering the first large batch of parts.
Ordered:
PULLEY3SXSOHCBELTS 3SX Custom Crank Pulley Stock
60KIT-3S-SOHC Mitsubishi OEM 60k Service Kit
MD974464 Engine Gasket Kit Complete
MD154251 Oil Pump - SOHC 91-95
CableAccelFWD-P2TB Throttle Cable - FWD Pedal
KnockSensorBracket3S Knock Sensor Bracket All 3S
BOLT-0058 BOLT-0058 - M10x20 Bolt Mount

[CoopKill]

Nice! Might check Ninja for faster shipping, and cheaper.

[Boost4VR4]

Nice! Might check Ninja for faster shipping, and cheaper.

I will have to check with Ninja, but I couldn't get a lot of the SOHC stuff with Ninja.

[Boost4VR4]

I ordered the valves and valve guides from GZP. Waiting for 3SX order to ship and GZP order to ship and I will have all of the engine components spoken for.

[Boost4VR4]

Made some small progress this past weekend, not a ton though...

Built the modular gauge cluster panel and the modular switches panel. I will be building the center console out this week, still trying to understand how I am going to design it. I think I am going to have to wing it... It will be a 2 piece design, 1 piece per side. I also ordered some CF vinyl wrap to finish the center console out, making it look presentable I suppose...

[Boost4VR4]

Made some small progress this past weekend, not a ton though...

Built the modular gauge cluster panel and the modular switches panel. I will be building the center console out this week, still trying to understand how I am going to design it. I think I am going to have to wing it... It will be a 2 piece design, 1 piece per side. I also ordered some CF vinyl wrap to finish the center console out, making it look presentable I suppose...

[Boost4VR4]

Alright here goes...

Valves and Valve Guides are here.

Waiting for more parts and CF vinyl.

[Boost4VR4]

CF Wrap arrived... Now I get to wrap the cluster...

[Boost4VR4]

Well I accomplished a few things, nothing very major, but it's better than nothing. I finished the gauges panel:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-9.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-9.jpg.html)

Here's the gauges in operation:

http://www.youtube.com/watch?v=mV-mQYx_QI4

Oh and a side note... I started the car for the first time in months, car sounds really bad, injectors are toast, fuel pump is barely pushing fuel and the engine is knocking pretty loudly. Thankfully this second engine is going to be getting a makeover so stay posted. PS: I caught some leaves on fire with the exhaust there were some flames under the car, nothing major.

I have talked around to more engine performance shops locally, it looks like I found a really good place to take this engine to that is local and has a genuine interest in helping my pursue my goals with this car.

[Boost4VR4]

Flywheel ordered.
Engine is going to machine shop tonight.

[Boost4VR4]

Engine is at machine shop, 1 month and I have a clean engine.

Heads have cracks in them, so on the lookout for SOHC heads...

[stealthee]

I may have a set in the basement. I cant remember if i trashed them or not. Let me check tomorrow.

[Boost4VR4]

I may have a set in the basement. I cant remember if i trashed them or not. Let me check tomorrow.

Let me know. I don't need the valves or cams...

[stealthee]

Just checked, must have junked them. Sorry Kev.

[sergechronos]

My local pull apart has a SOHC 3k (and a Diamante although unsure if those would be useful to you either) that I could snag heads off of for you to see this get built, but unsure of condition obviously. Heads themselves may be okay but I'm willing to wager that the internals are probably trashed.

[Boost4VR4]

Yea I am just needing a pair, I am still looking around a bit. I may have to ask GZP or check Ebay and make sure that the heads don't have a crack in between any of the cylinders and valves... I have the full valve train that I am using. I am looking at the engine manual and the diamante heads and 3/S heads for the SOHC are the exact same, so if you do have an opportunity to check the condition of the heads and if they are clean with no cracks I might want them...

I also made an interesting revelation over the last few days... Everyone says that there aren't any aftermarket options for connecting rods for the SOHC. Interestingly enough if you check the 6G72 Engine FSM, you will see that the connecting rod dimensions between the SOHC and the DOHC are the exact same. I was under the impression that these were different and everyone makes these out to be different, but they are the same. The big end journal and the small end journals are the same, wrist pin diameters are the same, length is the same. So I am going to order some forged connecting rods in the very near future so I can be sure that I have enough strength for the new power levels I will be introducing.

[sergechronos]

I won't be back up to the yard until Monday or Tuesday at the earliest. It's $60 per head, plus whatever it'd be to ship it. I think you're right about contacting Hans, or post in the parts wanted section and see if anyone has a set already laying around that they know are in good shape. These I wouldn't know until I took them off and would have unknown history as far as decking or anything else.

[Boost4VR4]

I won't be back up to the yard until Monday or Tuesday at the earliest. It's $60 per head, plus whatever it'd be to ship it. I think you're right about contacting Hans, or post in the parts wanted section and see if anyone has a set already laying around that they know are in good shape. These I wouldn't know until I took them off and would have unknown history as far as decking or anything else.

Are you talking 60 per head including valvetrain? if so, I don't need the valve train... I have new valve train stuff and camshafts.

[sergechronos]

It's 45 per head without cam shafts, plus a 10 core (per head). Unfortunately they don't have an option for just the bare heads.

[Boost4VR4]

OK check them and if they check out, I might want them...

[Boost4VR4]

Well, made some accomplishment today...

Made the switches panel, haven't put all of the switches in because I need to evaluate the wiring a little more and determine what I want to control by switch. I wrapped it just like the gauges cluster.

Pics posted:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-10.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-13-10.jpg.html)

[Uniuno]

Glad to see this build coming along.

There has to be a reason people said the conrods were different. Not that many people have built a SOHC motor with the availability of the DOHC and all.

As always, good luck!

[Boost4VR4]

Glad to see this build coming along.

There has to be a reason people said the conrods were different. Not that many people have built a SOHC motor with the availability of the DOHC and all.

As always, good luck!

I have found out that the differences are really in the construction of the rods and the rod studs are slightly different design, but everything else checks out.

[Boost4VR4]

Flywheel is in. Next step is to get the cylinder heads... and proceed onward with the clutch kit, solid motor mounts, and intercooler kit. I might also be able to snag up a single turbo exhaust manifold set someone is selling on the other forums.

[Uniuno]

Are the exhaust manifold flange patterns the same between SOHC and DOHC?

[sketch]

Are the exhaust manifold flange patterns the same between SOHC and DOHC?
i know that the exhaust ports on the heads are different (shape & size), don't know about the bolt pattern. pretty sure that those are different, too.

[Boost4VR4]

No I would be cutting the flanges off the already built manifolds and welding on new SOHC flanges. But to answer your question, the bolt patterns are the same.

[Uniuno]

I'm guessing there will be some modifications needed to make up for the different angles of the exhaust flanges and maybe even the distances between them. I bet the SOHC flanges are closer together than the DOHC. I'm just guessing though.

It should still be easier than starting from scratch lol

[Boost4VR4]

I'm guessing there will be some modifications needed to make up for the different angles of the exhaust flanges and maybe even the distances between them. I bet the SOHC flanges are closer together than the DOHC. I'm just guessing though.

It should still be easier than starting from scratch lol
Actually the spacing is the same from what I have seen. I will just need to weld very tight and it should be fairly easy.

DOHC:
http://www.ninjaperformance.com/images/MD168115.jpg
SOHC:
http://www.rockauto.com/getimage/getimage.php?imagekey=864447&imageurl=http%3A//www.rockauto.com/info/Corteco/506-18559.jpg

[Boost4VR4]

Project is on hold, buying a house... closing date is December 6th.

[Chris@Rvengeperformance]

Project is on hold, buying a house... closing date is December 6th.

no kidding? I'm closing on one on dec 4th.

It certainly puts a "hold" on some projects, lol. Gotta tow my car to the new place haha.

[Boost4VR4]

no kidding? I'm closing on one on dec 4th.

It certainly puts a "hold" on some projects, lol. Gotta tow my car to the new place haha.

Yea got a decent deal on a house here in MN. Not moving that far really, 20 minutes away, but now I own rather than rent. It's a seller's market here in MN, and it's been a very tough 3 months trying to lock in on a house. New place has a 40x30 pole barn and a hot tub building sitting on 1.5 acres, can't go wrong with that!

I gotta tow my car to the new place too. Engine is still sitting with the machinist, in a few weeks I am sure I will be getting a phone call asking for money or parts for the engine block. I still have to drop off the flywheel to the guy for the crankshaft balancing and call Ray Pampena for some connecting rods as well as a new set of heads since mine are cracked, likely going with Hans from GZP as he has a virtually new set of heads for a really good price. Those things I plan on getting after the move and everything settles down...

[Boost4VR4]

I did the unthinkable this morning...

Borg Warner s366 turbo ordered...

[Boost4VR4]

Everyone cares about pics... Here they are:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-7.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-7.jpg.html)

Muahahahaha!!!

[DocWalt]

Sweet! That should be a blast

[j2k4]

Sucking in MiniSoda...:)

[CoopKill]

Where ya puttin the engine?:surprise:

[j2k4]

You'll be needing a cow-catcher of some sort on that.

[Alex3000gt]

Everyone cares about pics... Here they are:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-4.jpg

Whose legs in the background?

[HilbillyHomeboy]

Whose legs in the background?

http://www.dudeiwantthat.com/entertainment/movie-props/A-Christmas-Story-Leg-Lamp-1617.jpg

[futurevr4man]

Bahahahahahaha it's the lamp from Christmas vacation!!

[Boost4VR4]

Bahahahahahaha it's the lamp from A Christmas Story!!
fixed...

[Boost4VR4]

Hey no thread derailment! It's all about the build!

Next on the list is connecting rods, exhaust manifold, and intercooler setup.

[Boost4VR4]

Going to run with stock manifolds and fabricate the exhaust cross pipe to the turbo. Using the stock manifold because it's very thick...
Connecting rods are on order as well as wastegate and dump tube.

[Boost4VR4]

New License plates:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-8.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-8.jpg.html)

[HilbillyHomeboy]

Vanity collector plates? I'm jealous; can't get those here.

Jeremy

[Boost4VR4]

Vanity collector plates? I'm jealous; can't get those here.

Jeremy

Yep, I inquired about it too because some states don't let you get vanity collector's plates. I believe my home state, Michigan, allowed you to get vanity collector's plates.

They were laughing when I told them the plate name. Actually, it was JasonY's plate idea and I liked it, so credit goes to him on the idea.

[Boost4VR4]

Oh boy, it's time to do work, son!

Here's the latest shipments that arrived today:

Ninja Performance Chromoly Forged Steel Connecting Rods:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-9.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-9.jpg.html)

Full Engine Rebuild Gasket Set:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-5.jpg.html)

Accessory Belts:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-20-5.jpg.html)

Be prepared to be blinded by 3SX harmonic balancer:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-4.jpg.html)

60k/120k Maintenance. That Oil Pump came straight from JAPAN!:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-4.jpg.html)

Knock Sensor bracket and bolts:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-3.jpg.html)

Throttle cable without cruise:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-2.jpg.html)

External Wastegate with dump tube will be showing up tomorrow.

[sketch]

nice~!

[mb3000]

Looking good!

[anyonebutme]

You're going to hate that non-cruise cable when you unpack it, lol. it's loooooooong.

[j2k4]

Prezzies!

[stealthee]

it's loooooooong.

That's what she said

[DocWalt]

Sweet!

[CoopKill]

Water pump?

[Boost4VR4]

Water pump?

Yea the water pump is in the upper right corner. Oil pump is below that.

[Boost4VR4]

Ok so I got the wastegate today.

They shipped two on accident, so I am being a gentleman and sending the one back.

CX Racing 38mm External Wastegate with 16PSI spring:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-10.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-10.jpg.html)

Two Wastegates!:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-6.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-6.jpg.html)

[ItTricky]

damn buddy, looks like you're coming right along.

[j2k4]

Jealous of your pile-o-parts, Kev. :)

[Boost4VR4]

Ordered Maximal Performance Solid Motor mounts and Brownline Digital Torque Wrench.

[Boost4VR4]

So I had a post on the other forums regarding the wastegates leaking on the plunger side, so I thought I'd explain what some of the parts in the wastegate kit are.

You have the basic wastegate:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-6.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-6.jpg.html)

Note the surface of the ring is opposite that of the plunger in the wastegate as if to make a seal. However when you place the ring in this flange, it hits the plunger:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-23-4.jpg.html)

You need to put a vacuum pump on one of the nipples on the wastegate and pull the plunger back with vacuum. In my case, I was testing the amount of vacuum required to pull the plunger back:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-11.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-14-11.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-7.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-17-7.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-21-5.jpg.html)

Note, this is what the ring looks like when the plunger is down:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-3.jpg.html)

Then insert the ring with plunger up:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-22-5.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-2.jpg.html)

If you have a collection pipe like I do with the flange already welded on, you will want to insert the gasket and put your flange on and tighten it:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-26-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-26-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-1.jpg.html)

Now you will have the wastegate sealed and it should barely leak any air, a little is OK. You can pressure test it by hooking it up to an air compressor. I haven't pressure tested it on the valve side yet.
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28.jpg.html)

[Boost4VR4]

Here's a really good guide on installing external wastegate:

http://www.treadstoneperformance.com/prod_imgs/installation/ul/install-112.pdf

[Erron Spalsbury]

That's the same type of gates that I'm using as well. They do work great. The gaskets however cook up and blow out fast. I made a set from sheet copper that hold up much better than what they come with. Thin sheet too, cut the outter portion with a pair of scissors.

[Boost4VR4]

That's the same type of gates that I'm using as well. They do work great. The gaskets however cook up and blow out fast. I made a set from sheet copper that hold up much better than what they come with. Thin sheet too, cut the outter portion with a pair of scissors.

Good tip, Erron, I was thinking about that too, these ceramic looking gaskets look like they will get brittle fast.

[Boost4VR4]

Ordered Synapse Synchronic BOV.

[Erron Spalsbury]

Good tip, Erron, I was thinking about that too, these ceramic looking gaskets look like they will get brittle fast.

Yes sir. Mine came with those and if memory serves they lasted about 20 minutes on the track. I think they just burn up, crack, then blow out.

[Boost4VR4]

Yes sir. Mine came with those and if memory serves they lasted about 20 minutes on the track. I think they just burn up, crack, then blow out.

I should be able to cut anything I want now that I have a bandsaw in the garage. I can cut out some meaty wastegate gaskets.

[Alex3000gt]

Garage pics, please.

[Boost4VR4]

Alright, I will post up some garage pics so far... it's always a Work in Progress.

[CoopKill]

2 hrs and no pics...

Sent from my SM-N900V using Tapatalk

[mb3000]

What a shame..

[Boost4VR4]

Easy fellas... I will get to it. I will be working in the garage tomorrow so I will snap some garage shots. And the car too.

[sketch]

Easy fellas... I will get to it. I will be working in the garage tomorrow so I will snap some garage shots. And the car too.

sometimes, i doubt your commitment to sparkle motion.

[Boost4VR4]

sometimes, i doubt your commitment to sparkle motion.

I didn't venture out into the -25F degree weather yesterday...

[Boost4VR4]

Maximal Solid mounts came a couple days ago.

I am for sure going to venture into the garage/pole-barn and get some pics, organize the parts for the car, etc since it's about 20 degrees (better than -28 that we are getting this weekend.) Stay posted.

[Alex3000gt]

I am posted.

Where are those pics!

[Boost4VR4]

I am posted.

Where are those pics!

Coming Meow! Sorry if they are blurry... must be something on the lens...

http://i869.photobucket.com/albums/ab253/kevpi1/temporary-22.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-22.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/temporary-21.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-21.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/temporary-17.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-17.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/temporary-14.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-14.jpg.html)

[Alex3000gt]

Coming Meow! Sorry if they are blurry... must be something on the lens...

http://i869.photobucket.com/albums/ab253/kevpi1/temporary-22.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-22.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/temporary-21.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-21.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/temporary-17.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-17.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/temporary-14.jpg (http://s869.photobucket.com/user/kevpi1/media/temporary-14.jpg.html)

Nice! You have a ceiling fan in your shop, not too useful in January but it'll help in July!

[Boost4VR4]

Ordered entire intercooler setup and piping.

[mb3000]

^Nice! What did you go with?

[sketch]

Ordered entire intercooler setup and piping.

whatcha get!? you can't just tease with "i bought something" and then not tell us what you ordered!

[Boost4VR4]

whatcha get!? you can't just tease with "i bought something" and then not tell us what you ordered!

Ok here's the list then:

1 x Silicone Reducer, 4.0" to 3.5" - Black
1 x 3.0" Silicone 1' Straight Hose, Black
1 x T-Bolt Clamp for 4.5" Silicone Parts
1 x T4 Turbo Blanket
1 x Water to Air Ice Box Reservoir
1 x Water to Air Intercooler Pump and Harness, Bosch Cobra
1 x 12" Radiator Fan with Mounting Kit
1 x Water to Air Intercooler, 12.25"x12.25"x4.5", Bend I/O (Type 14)
1 x Dual-Cone Air Filter - black, 3.5" inlet
1 x Stainless Steel Joiner, 3.5"
2 x T-Bolt Clamp for 3.25" Silicone Parts
1 x Water to Air Intercooler Installation Kit (1200HP)

It's from Frozenboost.com. It's a Shaman core which I have heard had great reviews.

Next order will be from Summit Racing:

ICEngineworks 1750BASIC - ICEngineworks 1750 Series Basic Kits
T4 Flange
4 inch V-Band flange kit

[FeaRpb]

0o0o0o0o0o0o0o0o0o0o0o0oo0

Fancy fancy

[sketch]

1 x Water to Air Intercooler, 12.25"x12.25"x4.5", Bend I/O (Type 14)

this guy (http://www.frozenboost.com/product_info.php?cPath=218&products_id=214&osCsid=f8ae6880df0793701138e747338e9acb) ??

nice.

[Boost4VR4]

this guy (http://www.frozenboost.com/product_info.php?cPath=218&products_id=214&osCsid=f8ae6880df0793701138e747338e9acb) ??

nice.

Yep that one.

[CoopKill]

Noice!

[Boost4VR4]

Just ordered this morning due to engine builder requirements for crankshaft balancing:

MD974046 Thermostat OEM SOHC
BOLT-3400 BOLT-3400 - Bolt Flywheel to Crankshaft
BOLT-1251 BOLT-1251 - Bolt Pressure Plate
FuelPumpGasket3S Fuel Pump GASKET - OEM Mitsubishi
OilFilterAdapter-M20 Prosport Oil Filter Adapter
BattOdy-PC680 Odyssey Battery - PC680
ClutchComp3SNA5UnSpr Competition Clutch Kit 3S NA
KnockSensor3SNon Knock Sensor Non-OEM 3000GT

[mb3000]

Non-OEM knock sensor?

[stealthee]

SOHC doesn't come from the factory with a knock sensor. Only the 10:1 Diamante SOHC's came with knock sensors.

[Boost4VR4]

SOHC doesn't come from the factory with a knock sensor. Only the 10:1 Diamante SOHC's came with knock sensors.


I am adding a knock sensor, I have the knock sensor bracket and hardware.

[Alex3000gt]

I am adding a knock sensor, I have the knock sensor bracket and hardware.

Good idea!

[Boost4VR4]

Engine builder/machinist came back with invoice. Proceeding with adding ARP Main studs and head studs for strength and durability. Once clutch kit comes in, sending everything off to the machinist and getting the block back in a few weeks!

[Boost4VR4]

I got the whole intercooler setup minus the heat exchanger. I didn't get the heat exchanger yet because I need to pull the bumper off to get an idea on what kind of room I will need.

Did some work on the car last night.

Had a friend come over and help with some stuff.

Removed the hood, charcoal canister, throttle cable, all intake parts, coolant bottle, outer fender bolts. Removed solenoid rack on the firewall and charcoal canister line, hard line is removed too.

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-26-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-26-2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-3.jpg.html)

I then did a quick mock-up of the intercooler and turbo locations.
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-4.jpg.html)

[DocWalt]

Geez, that thing looks massive, even down there. I like how short the intake piping will be, should have great response.

[Boost4VR4]

Geez, that thing looks massive, even down there. I like how short the intake piping will be, should have great response.

Yea that's what she said...

It is a large turbo... should be interesting with the short run to the intake...

Got the Synapse BOV in... Pretty nice BOV... hope it holds the boost... I assembled it... Good thing I have an aluminum intake coupler/spacer to weld this on to!

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-5.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-24-5.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-25-4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-3.jpg.html)

[Boost4VR4]

Machinist said block is out getting all done up. Shot peened, magnafluxed, cleaned. Once it comes back it will be getting decked, line honed, bored, pistons hung, clearanced, and crankshaft turned, balanced, cleaned.

[Boost4VR4]

Dropped deposit off with machinist.
Crankshaft is polished, didn't get a pic of it before I left, but its very shiny.

I got some work done today. Pulled air conditioning lines, removed excess brackets, removed headlights, removed fenders, removed front bumper. Pretty good progress for the day.
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-31-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-31-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-29-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-29-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28-1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-4.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-30-1.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-30-1.jpg.html)

[Alex3000gt]

Hurricane Wheels! Yes!

[Boost4VR4]

Clutch kit arrived:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-5.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-5.jpg.html)

Also almost all of the parts shipped from 3SX, still waiting on an Odyssey battery, but everything else should be coming.

[Boost4VR4]

I'm really trying to get as much as I can done on this car, but it is very difficult when it's below zero most days. Even the heater doesn't really help that much when it's below zero. I did miss the one good day this past Sunday it was in the 30s, but I decided that it was best spent outside with the gf.

So what I am hoping to accomplish in the next couple weeks or so:

Remove ABS Lines and ABS Pump
Order ABS Delete Kit
Install ABS Delete Kit
Remove Radiator and swap the fans
Remove Air Conditioner condenser
Reinstall Radiator
Install Icebox
Install icebox drain valve and tubing through passenger floor
Install water lines through firewall
Install Intercooler water pump
Pressure test intercooler core
Decide on heat exchanger core size and order
Create ducting for heat exchanger and install heat exchanger and heat exchanger fan
Drop the downpipe and pull full exhaust off car and sell
Sell CarPC setup with speakers

[stealthee]

You have ABS on a SOHC?

[sketch]

according to his photos, he does, yeah.

[stealthee]

Yeah, after I posted that I went back up to see if the photos showed the lines or not and was shocked to see them.

I agree, ditch the ABS.

[Boost4VR4]

New heads are coming, should be here tomorrow. Then I can send them to the machine shop and have the guides and stem seals pressed in as well as cleaning the heads and doing some exhaust porting.

[Boost4VR4]

Flywheel bolts and pressure plate bolts arrived along with everything else. Dropping off clutch kit with bolts to the machinist today and hopefully tackling some work on the car.

[Boost4VR4]

I dropped off clutch kit with flywheel and pressure plate bolts to machinist. Pretty wicked weather today.

Well I got some things taken care of on the car, but some bad things happened...

I pulled the radiator, air conditioning condensor, lines and installed throttle cable without cruise.

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28-2.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28-2.jpg.html)

I tried to salvage the radiator since it seems to be in decent shape, however, the radiator fan bolts were rusted bad and I could only get 3 of the 4 on both fans. I pulled the fans off and one pulled the mounting tab on the radiator creating a hole and the other one broke off at the ear. Looks like I need to add a radiator to the list.

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-6.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-6.jpg.html)

[mb3000]

Shouldn't be too hard to pick one up from the classifieds. I know mine was absolutely trashed when I pulled it out :lol:

[Uniuno]

I have a spare tt radiator that is like brand new I'll give you cheap.

Sent from my HTC One using Tapatalk

[Boost4VR4]

I have a spare tt radiator that is like brand new I'll give you cheap.

Sent from my HTC One using Tapatalk

PM me price...

I am looking at OEM replacements around 199 which is an aluminum type.

[Boost4VR4]

Cylinder heads showed up. I now have everything engine related accounted for.

[CoopKill]

Done yet?

[Boost4VR4]

Machinist has engine waiting for short block to be built.

This build will be on a temporary hold/slower progress since I picked up a new car. Keep posted for pics in Other Platforms.

Teaser: 2008 BMW 535xi (I6 Twin Turbo AWD)

[Boomer3000]

This thread needs more pictures!!!

[Boost4VR4]

This thread needs more pictures!!!

OK fine.

I installed the intercooler water pump and lines and quickly mocked up the ice box. Looks like the passenger seat will be removed.
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-7.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-27-7.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28-3.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/temporary-28-3.jpg.html)

[TT4ME]

Please get a camera or a better phone.

Thanks

[Boost4VR4]

Please get a camera or a better phone.

Thanks

I will have to clean the lens for you people demanding 1080p resolution!

[TT4ME]

I will have to clean the lens for you people demanding 1080p resolution!

FYI - I don't think resolution is the problem... Maybe cleaning the lens will help? All your pics are horribly washed out. If I went through the work of a build thread, I'd like the pics to be quality (for my own reference and for the people watching.) For example, view Jimvr4's thread starting around post 260 http://www.3sgto.org/turbo-engines-systems/10526-jimvr4-95-spyder-engine-rebuild.html . It's beautiful! You could do the same!

[DocWalt]

^^ lol

[Alex3000gt]

Don't mind Dave, he's an ISTJ 'Inspector' personality.


However, ISTJs more often tend to believe that things should be done according to procedures and plans. If an ISTJ has not developed their Intuitive side sufficiently, they may become overly obsessed with structure, and insist on doing everything "by the book".

...

ISTJs are quiet and reserved individuals who are interested in security and peaceful living. They have a strongly-felt internal sense of duty, which lends them a serious air and the motivation to follow through on tasks. Organized and methodical in their approach, they can generally succeed at any task which they undertake.

[Uniuno]

Most people put the ice box in the trunk so they can haul people. Just a thought.

Sent from my HTC One using Tapatalk

[Boost4VR4]

Thanks to Uniuno, I now have a replacement radiator. It was in great shape and it's an OEM TT Radiator so it should work just fine for my application.

I fixed as many fins on it as I could to keep it looking decent and useful.

I think I may be able to mount the icebox transverse and save the front passenger seat so I can have a passenger. Only problem is there won't be a footwell.

[Boost4VR4]

Odyssey battery shipped, should see it next week.

Been saving money to put down on the BMW.

[sketch]

which model odyssey did you get?

[Boost4VR4]

Pc680

[Boost4VR4]

Welp, been awhile since the last post. I got a new toolbox for my tools and got some new tools, looking to add more to the toolbox, but for now, I am just waiting a bit on tools.

I have received some confirmation that next week the engine will be finished. It took a bit because the machinist ordered ARP girdle and head studs and they sent out 4 bolt TT studs which didn't have the correct thread pitch nor were they correct length. He got the replacements in on Friday. He has the crankshaft balanced with clutch, flywheel, he will be balancing again with the connecting rods and pistons. Really stoked to see this completed engine!

[DocWalt]

I guess ARP was just as surprised as most people when you ordered SOHC parts :)

[Boost4VR4]

So ordered some small things to get me going on the intercooler setup:

1 x 12" Radiator Fan with Mounting Kit
1 x Water to Air Intercooler Radiator - 24x12x1 (Type 100)
10 x 3/4"(19mm) ID water hose, black (per foot)
2 x Brass 1/2" NPT Male to 3/4" Barbed Straight
6 x Stainless Steel 1" Worm Gear Clamp (14-27mm)

[Boost4VR4]

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0349.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0349.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0351.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0351.jpg.html)
Heat exchanger with both 12 inch fans mounted. Will be making a special bracket for mounting these fans, for now, used the zip ties included in the kit for mock-up. Compared this to the OEM radiator. With the fans mounted plus the thickness of the heat exchanger, it's only 2 inches thick.

[DocWalt]

That's a really nice piece!

[Boost4VR4]

Well, I got my first taste of slight defeat in terms of working on this car...

I was test fitting the heat exchanger and a few things came up:

First I took the radiator shroud, horns, and structural piece for hood latch out:
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0367.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0367.jpg.html)
Power steering lines running to the front of the car behind the crash bar. I removed this extra length of line and use a brand new line and ran the line straight to the reservoir:
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0370.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0370.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0368.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0368.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0371.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0371.jpg.html)
From the steering rack:
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0377.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0377.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0379.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0379.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0380.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0380.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0381.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0381.jpg.html)
Ridiculous long hard line gone:
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0382.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0382.jpg.html)

So then the next dilemma was getting understanding how the heat exchanger was going to be mounted. I removed the crash bar and started working on the bump strip on the bottom of the front frame member. I fabricated a section of 90 degree aluminum sheet and test mounted it:
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0385.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0385.jpg.html)
Then I needed another 90 degree bracket to hold the heat exchanger. The heat exchanger won't fit behind the bumper if it is mounted vertical, so the heat exchanger will need to be mounted diagonally. Fans in the front will pull UP the air and draw it through.
http://i869.photobucket.com/albums/ab253/kevpi1/DSC_0383.jpg (http://s869.photobucket.com/user/kevpi1/media/DSC_0383.jpg.html)

More to come tomorrow.

[B-Man]

FYI, that power steering line that runs by the crashbar is a cooler. I'd at least run it through a cheap fin and tube type cooler where there's a little airflow.

[Boost4VR4]

FYI, that power steering line that runs by the crashbar is a cooler. I'd at least run it through a cheap fin and tube type cooler where there's a little airflow.

I am probably going to replace it with an inexpensive power steering cooler from pep boys. I looked online and it's a pretty small cooler that I can put in the foglights area. For now, it's staying re-routed. The steering rack is leaking anyways so I will need to pull it. Right now, I am just mocking stuff up temporarily and then removing it.

[Boost4VR4]

So some quick updates:

I made the new heat exchanger tray and mounted it to the frame member. I did a quick mockup of how the heat exchanger is going to mount and had a problem with the fans. I believe I mounted them backwards, so I will need to mount them on the other side of the exchanger. Then I ran some water lines where they are going to run and I have a good idea of how it needs to work. Here's some progress:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0387.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0387.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0389.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0389.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0390.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0390.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0391.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0391.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0392.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0392.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0394.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0394.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0395.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0395.jpg.html)

[Boost4VR4]

Ordered inexpensive 350z exhaust manifolds to test mock up of turbo. More to come.

[Boost4VR4]

Ordered Megasquirt II Assembled Kit

[Chris@Rvengeperformance]

would've went aem personally

[Boost4VR4]

would've went aem personally

I thought about it, however, the Megasquirt II is more in line with my budget for this build. Plus the Megasquirt comes with:

(1) MS2357-C MegaSquirt-II PCBv3.57 ECU
(1) BIP373 Ignition Module
MOD_x357-12VIN ECU Mod for the LT1 Ignition-- 12V pull-up on the ignition input
MOD_230-IGBT1 Single Ignition Output through IGBT (BIP373 Installed/Enabled)
(1) MSStim22-C MegaSquirt Stimulator version 2.2
(1) MSHarness8 8' Pigtail Wiring Harness
(1) IATwPiggy IAT sensor
(1) CLTIATwPiggy Coolant temperature sensor
(1) 38NPTBung-A Aluminum IAT sensor bung
(1) TuneCable6 Tuning Cable for MegaSquirt EMS
(1) USB-2920 USB Adapter needed for most laptops
(1) decal161 Snazzy DIYAutoTune.com decal
(1) Free T-shirt, if you remember to tell us the size you want in your order comments (S, M, L, XL)

All of this is 1/4th the cost of an AEM setup. Plus I couldn't find an AEM setup that was pinned out correctly for a SOHC harness, so I would have to build out a custom harness, here I have the harness.

[Chris@Rvengeperformance]

makes sense

I guess it wouldn't work to convert to convert to a DOHC type setup and run chrome? I know the ignition would be totally different and the harness is a lot different. I just know you are kinda on your own with megasquirt for us.

[Boost4VR4]

I thought about running AEM and getting a harness extension and re-running the pinouts, however, this will be mostly plug and play. There are far less pinouts on the SOHC than the DOHC.

The tuning is the same as AEM on the megasquirt.

[DocWalt]

You still have to build the other end of the harness :p DIY's harnesses are VERY nice though. If you have any basic MegaSquirt questions, let me know.

[Boost4VR4]

You still have to build the other end of the harness :p DIY's harnesses are VERY nice though. If you have any basic MegaSquirt questions, let me know.

Yea I know, but I can take all of the crappy stock wiring out and use the harness.

[Boost4VR4]

Well I received the 350z manifolds and for the most part for 89 dollars I can't really knock the quality too much... I mean the collector wasn't skillfully made well, but I applaud their effort. It's a good starting point:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0418.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0418.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0415.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0415.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0414.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0414.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0413.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0413.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0412.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0412.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0411.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0411.jpg.html)

Here's the SOHC gasket lined up with exhaust ports of this manifold (gasket is on backwards, but even flipped, runners still line up):
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0420.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0420.jpg.html)

The runners would need to be made round again, but nothing major.

[mb3000]

How thick is the material on there?

[Chris@Rvengeperformance]

wow those are shitty inside. I would do some porting to be sure you aren't going to have chunks of pipe go through your turbo

[Boost4VR4]

How thick is the material on there?
304 SS

wow those are shitty inside. I would do some porting to be sure you aren't going to have chunks of pipe go through your turbo

They are shitty inside, I will either A. Redo the collector or B. have the material ground down so it isn't so ugly.

[mb3000]

304 SS is what they are made of. Is there any way you could stick a caliper on there when you cut off the 350z flange?

[Boost4VR4]

They are 16 gauge from my understanding.

[mb3000]

Really curious as to how they hold up. They seem to fit perfectly, I seriously considered running them for a while now. Just couldn't get over my fear of them cracking/not holding up. Seems like everyone that has used them only uses them for a short amount of time and then changes it up.

[Boost4VR4]

Really curious as to how they hold up. They seem to fit perfectly, I seriously considered running them for a while now. Just couldn't get over my fear of them cracking/not holding up. Seems like everyone that has used them only uses them for a short amount of time and then changes it up.

There is a possibility of them not holding up, but I needed something to work with to start getting the turbo placed in the engine bay. I didnt want to spend hundreds of dollars on a manifold set only to hack them up for fitment and then have to spend hundreds again on newly fabricated manifolds. I went this route so I can get a test set and not worry about hacking them up too much during fabbing and once I felt confident of the turbo placement and the manifolds design, then I can send it to a fabricator and have them make a full setup and I will spend the hundreds there.

[mb3000]

Pretty good idea, did you have any place in mind? I know there's a couple of "Internet" shops you can send things like that to, but don't know which one(s) would be best.

Really excited to see what numbers you throw down after it's all said and done. Might have to pick up another SOHC... :bigthumb:

[Boost4VR4]

Pretty good idea, did you have any place in mind? I know there's a couple of "Internet" shops you can send things like that to, but don't know which one(s) would be best.

Really excited to see what numbers you throw down after it's all said and done. Might have to pick up another SOHC... :bigthumb:

I haven't figured it out yet. I need a local fab guy to help with some of it then I can take the finished mock-up somewhere.

[mb3000]

Here we go, this is the place I had in mind.

http://www.stainlessheaders.com/customheaders

[arm0red1]

Mine on my single held up fine, the only reason they came off is to test the prototype td04's ive been developing in parallel to fabbing my own single kit. I plan to return to single after these have been thoroughly demo'd.

If you wanted to add a level of durability to the unit, weld a support rod to where the runners collect to the corner of the flanging that goes to the cyl head. You can also consider some small form of reinforcement or gussets below the runners to ensure no cracking occurs. Finally welding quenches metal and causes it to pucker around the weld bead, adding surface tension, a fab trick I learned from a street rod fabricator is to peen the weld bead after you're done to relieve surface tension at the weld and reduce the chance of cracking from stress/fatigue at that area

An example of this occurance would be the earlier 3sx td05 headers that cracked at the welds regularly after being ran for awhile. Thin gauge steel with innate surface tension causing a thin spot on already thin guage = no bueno.

I also got into where the collector merges with a pneumatic carbide bit and removed a good 1/8"- 3/16" of ridge from the pipe merge and welding. Lots of turbulence issues you can address there to preserve spoolup and not waste exhaust energy unnecessarily.

Hope some of this helps! Gl it's time consuming, but a fun project!

[Boost4VR4]

Mine on my single held up fine, the only reason they came off is to test the prototype td04's ive been developing in parallel to fabbing my own single kit. I plan to return to single after these have been thoroughly demo'd.

If you wanted to add a level of durability to the unit, weld a support rod to where the runners collect to the corner of the flanging that goes to the cyl head. You can also consider some small form of reinforcement or gussets below the runners to ensure no cracking occurs. Finally welding quenches metal and causes it to pucker around the weld bead, adding surface tension, a fab trick I learned from a street rod fabricator is to peen the weld bead after you're done to relieve surface tension at the weld and reduce the chance of cracking from stress/fatigue at that area

An example of this occurance would be the earlier 3sx td05 headers that cracked at the welds regularly after being ran for awhile. Thin gauge steel with innate surface tension causing a thin spot on already thin guage = no bueno.

I also got into where the collector merges with a pneumatic carbide bit and removed a good 1/8"- 3/16" of ridge from the pipe merge and welding. Lots of turbulence issues you can address there to preserve spoolup and not waste exhaust energy unnecessarily.

Hope some of this helps! Gl it's time consuming, but a fun project!

This is all greek to me, I will have someone else fabricate this setup for me.

[familyMAN]

3sx rear runner welds have no penetration. When I say "no" I mean zero, zip, zilch, none. The welds are basically cosmetic. Just going over them with good penetration and a little filler would prevent a lot of issues.

[Boost4VR4]

Well these manifolds are welded through, I can see the penetration. I just need to clean up the collector area.

[j2k4]

Well I received the 350z manifolds and for the most part for 89 dollars I can't really knock the quality too much... I mean the collector wasn't skillfully made well, but I applaud their effort. It's a good starting point:
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0418.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0418.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0415.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0415.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0414.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0414.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0413.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0413.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0412.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0412.jpg.html)

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0411.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0411.jpg.html)

Here's the SOHC gasket lined up with exhaust ports of this manifold (gasket is on backwards, but even flipped, runners still line up):
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0420.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0420.jpg.html)

The runners would need to be made round again, but nothing major.

You've just met, and you're already in bed?


Slut...:rolleyes:

[Boost4VR4]

You've just met, and you're already in bed?


Slut...:rolleyes:

Lol... not sure how to respond to this, I guess I will respond with pics

Reserved for pics...

[Boost4VR4]

And the really good stuff showed up, now the fun commences!
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0430.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0430.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0429.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0429.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0428.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0428.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0427.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0427.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0426.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0426.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0425.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0425.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0424.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0424.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0423.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0423.jpg.html)

[j2k4]

Do you sleep with all your parts, Kev? :huh:

[FeaRpb]

Looks like it should be fun to setup.

[Boost4VR4]

Do you sleep with all your parts, Kev? :huh:

Sure, it gives me good luck! LOL.

[DocWalt]

:encouragement::bigthumb:

[Boost4VR4]

Engine pics from machinist and builder:

http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/20140403_231813.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/20140403_231813.jpg.html)
I already asked about why there are only 12 head studs when there should be 16 as well as if there are included nuts for the head studs since the OEM head studs are basically long bolts and these are a different design. Also the knock sensor that the DOHC engines have has been tapped into the block in basically the same location as the DOHC engines which will be very helpful.
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/20140403_231912.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/20140403_231912.jpg.html)
Ninja Performance Chromoly Connecting rods are in there and the Wisecos are in there too.

Will be dropping off the heads, valve guides, valve seats and the associated cylinder heads hardware off to machinist for a cleaning and to press in the guides and seats. I will assemble the heads with the new cams and associated valves and hardware.

Found out that everything is well, the other studs are not installed because the dowels are not in place. The hardware is included as well.

[Chris@Rvengeperformance]

Pics aren't the clearest, but looks like a decent cylinder bore finish. Are you going to degree the cams?

[Boost4VR4]

Pics aren't the clearest, but looks like a decent cylinder bore finish. Are you going to degree the cams?

Yea I will be degreeing the cams once I get it on my stand.

Yea the pics are pretty blurry, I will be bringing my camera to get better pictures.

[Chris@Rvengeperformance]

looked a little closer, damn he had to swiss cheese the counterweights.

[Boost4VR4]

looked a little closer, damn he had to swiss cheese the counterweights.

Crankshaft is balanced with 3SX lightweight stock sized crank pulley and the lighter pistons and connecting rods, that is why they are drilled out so much. The clutch kit was also attached and the crankshaft balanced with that as well.

[Boost4VR4]

Here's some better pictures of the engine. It looks like the builder took a lot out of the crankshaft and it also looks like he drilled too close to another hold on the crankshaft, see if you can spot it.
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0011.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0011.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0010.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0010.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0009.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0009.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0007.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0007.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0006.jpg (http://s869.photobucket.com/user/kevpi1/media/Beater%20car/SOHC%20TURBO%20ENGINE%20BUILD/DSC_0006.jpg.html)

[Boost4VR4]

Well, things are starting to ramp up again. Will be doing tons of car work this weekend. Ordered Milspec connectors for the engine harness and circuit breakers to replace fuses. It will be a nice little wiring weekend. I am hoping to start really tearing into the car now.

[Chris@Rvengeperformance]

I just don't have a great feeling about that balance job, but the rest of it looks good. The cylinder wall finish looks good

[Boost4VR4]

I just don't have a great feeling about that balance job, but the rest of it looks good. The cylinder wall finish looks good

I think the balance job will be fine. The Ninja Performance Chromoly Forged Connecting rods are 90 grams lighter than stock and the pistons are much lighter as well plus I have a stock sized billet crank pulley going on this which is significantly lighter.

[j2k4]

I think the balance job will be fine. The Ninja Performance Chromoly Forged Connecting rods are 90 grams lighter than stock and the pistons are much lighter as well plus I have a stock sized billet crank pulley going on this which is significantly lighter.

Kevin, I'm gonna say this as a noob with no personal experience inside the crankcase of this platform (I also wish to assure you I mean no offense) - it that thing stays together, it should fly.

If it doesn't, that ^^ is where it will likely fail.

Again, I'm rooting for you, not the Japanese engineers. :)

[Boost4VR4]

Hype Hype Hype!

Engine comes home tomorrow evening. Everything is done and ready to go. Tomorrow we are going to drop the cams in to make sure they will fit through the bore and see if it will need a line bore through the cam caps.

Other than that, everything else is good. Will be snapping pictures tomorrow.

[Uniuno]

Woo! it'll be running by this weekend, right!?!

Looking good Kevin, the new camera is a big improvement.

[Boost4VR4]

Woo! it'll be running by this weekend, right!?!

Looking good Kevin, the new camera is a big improvement.

I wish... lol still have a lot of work ahead, lots of fabricating, wiring and getting the engine running with the turbo.

[Boost4VR4]

Shortblock is back. Now it's time for assembly!

Oh, and we dropped the cams in the new heads and put the camshaft sliders, rockers, caps on and tested the camshaft rotation. Camshafts rotated with no effort at all even with the bolts tightened down so no need to line bore the heads.