Big Single Build

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

Quote:

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Originally Posted by 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.

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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.

you have a PM Boost

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...

Picking up a 2nd SOHC engine to build on.

Here's the updated parts list:
https://docs.google.com/spreadsheet/...rbnU1bGc#gid=0

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.

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/a...mporary-14.jpg
http://i869.photobucket.com/albums/a...mporary-13.jpg
http://i869.photobucket.com/albums/a...mporary-15.jpg

Off comes the Throttle body:
http://i869.photobucket.com/albums/a...mporary-16.jpg
IAC and TPS pulled injectors are not for this car, they are for a Jaguar XJR:
http://i869.photobucket.com/albums/a...mporary-17.jpg
Components off the back of the intake plenum:
http://i869.photobucket.com/albums/a...mporary-18.jpg
Plenum Pulled:
http://i869.photobucket.com/albums/a...mporary-19.jpg
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/a...mporary-20.jpg
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/a...mporary-21.jpg
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/a...mporary-22.jpg
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/a...mporary-23.jpg

Good progress so far :)

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/a...orary-18-1.jpg
http://i869.photobucket.com/albums/a...orary-17-1.jpg
Here's where the low compression issue was:
http://i869.photobucket.com/albums/a...orary-20-1.jpg
http://i869.photobucket.com/albums/a...orary-14-1.jpg
For the most part, everything looks good, cylinder walls are smooth.a

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.