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Old 09-25-2013, 10:09 PM   #1
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Default EFR6258 on a VVT W PS/AC

Well, it is not done yet, but it is up and running.....STRONG!
I am sure I will forget a lot of what I did but here goes my attempt at a build thread.....

I started with a VVT head. Had SuperTech (ST) +1 valves installed on both the intake and exhaust. I used the light dual spring setup by ST. I installed new bronze guides after the head was ported and polished resulting in more than a 20% increase in flow. I had it flow benched for possibly ordering custom cams at a later date.

Lots of rough casting flash....





Then a little of this happens....





we get this next








New guides







Then we flow benched it to see the improvements



final assembly on the head leaves us with


Cleaned all the hidden places and replaced the O-rings

Attached Thumbnails
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Old 09-25-2013, 10:18 PM   #2
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very cool!

is this little ding going to cause any problems?

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Old 09-25-2013, 10:38 PM   #3
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No, I just checked and that cleaned up when we surfaced the head. Good eye!
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Old 09-25-2013, 11:16 PM   #4
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After the head was done I balanced the ST 8.6:1 83.5mm pistons and Manley rods. Installed the ARP main/head studs. Boundary Engineering Extreme oil pump, ATI Damper, and ACL Race bearings.


Pretty painted block



Lots of this stuff


Block was resurfaced and line bored




94-00 head gasket installed properly


Gates Racing timing belt




Adjustable cam gear for exhaust side to maximize tune ability to increase low end spool since that was the main goal of this build....



Continuing with the mindset of spool over maximum flow I made a low volume exhaust manifold based on the Absurd flow design out of schedule 40 mild steel weld els from the local plumbing supply house.


Little ugly but hey, it was my first one and I was using flux core wire! 0.035 at 185amps on 220V Lincoln welder



I used a die grinder to clean up the inside ports.....


Then I bought a Tig welder and started getting experience. I welded a -6AN fitting to the water pump and drilled through it to allow my turbo coolant to return to the system before the pump.





Stainless oil/coolant lines with AN fittings for the clean professional installation. Really happy with the look of the black fittings over the bling bling blue/red.




To route the coolant from the heater core to the water pump I wanted to avoid the down pipe area so I cut the steel line that fits into the housing and welded a bead around the end to prevent the hose from coming off. I welded a tab to hold it in place with one of the bolts that secures the PS pump to the block. Notice the second O-ring? Ask me why it is there.....lets just say you should remove it before welding the pipe, even if you think you are keeping it cool.....





The piece is sitting on my 49" belt sander that I found indispensable while fabricating my exhaust and IC charge pipes.



I am happy with my tig welding skills for a self taught noob



A slight modification to the bumper support to allow clearance of the FMIC









I used 3" mandrel bent aluminized 16ga steel for the exhaust. I used two 18" resonators and the big dog Magnaflow muffler.



Attached Thumbnails
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EFR6258 on a VVT W PS/AC-midpipe.jpg   EFR6258 on a VVT W PS/AC-downpipe.jpg  
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Old 09-25-2013, 11:17 PM
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Old 09-25-2013, 11:40 PM   #5
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Before



After


I cut the package shelf at the firewall like the guys who do V8 swaps to give me more room for the down pipe. I cut it, welded in a piece of like sized sheet metal, then used seam sealer from a auto body supply shop ($23 a tube!!!), and painted it with made to order matching enamel paint.
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EFR6258 on a VVT W PS/AC-img_3218.jpg   EFR6258 on a VVT W PS/AC-efr%252520body%252520mod.jpg  
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Old 09-26-2013, 01:19 AM   #6
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Wow man that all came out great, especially for your first time! Welding looks good, especially the aluminum.
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Old 09-26-2013, 01:33 AM   #7
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Thanks! I am pleased with it....
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Old 09-26-2013, 01:39 AM   #8
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so I take it you had a blast driving it this weekend?
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Old 09-26-2013, 01:52 AM   #9
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Hell yeah! I put 1300 miles on in three days of canyon carving in the mountains of NC/TN/VA. Not a bad test for my build I think? It had about 150 miles on it before I headed up the hill. There were about 120 miatas there, my guess is 20 were forced induction. I was definitely one of the fastest ones there and I was, am, still learning my setup. Just before going to the event I put on new wheels (9" 6UL), tires (225 Rivals), and shocks (Ohlins DFV) plus I tripled the power so the car was all new to me. I love how the EFR spools coming out of the corners. Can't wait to get the EBC and knock control working properly to really experience what this car truly has. I did discover I will be in the market for a BBK in the near future! One run coming down the mountain found my HPS pads at their limit!
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Old 09-26-2013, 08:16 AM   #10
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How does the car sound with the two resonators and the muffler? I imagine it's fairly quite in cruise and low throttle?
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Old 09-26-2013, 08:21 AM   #11
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Extremely quiet! Stockish? There is a deep rumble when you get on it in boost, but idle and low throttle is very quiet and civil.
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Old 09-26-2013, 09:54 AM   #12
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Very nice DIY fab and parts selection!
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Old 11-06-2013, 10:00 PM   #13
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You really don't cut corners man! How about some videos of in-car mountain runs or dyno time? In for numbers and maybe I'll see this car in real life sometime.

I wish I could weld and make my own everything like you. What injectors are you using? MS3?
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Old 11-06-2013, 10:08 PM   #14
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Thanks!
ID 850's, Reverant built MS3 with extras.
Come west and we will hit the mountains together! The car is a lot of fun....I will try to post some video soon..... I hope to dyno next week and will post results then. I am not happy with the results from the first trip to the dyno (305/310).
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Old 11-06-2013, 10:21 PM   #15
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I will be sure to come out west. New to the state and haven't gotten out to the smoky mountains yet... such shame.

What empirical data differences did you get from the flowbench? I've been wondering what true gains fine head work like that yields.
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Old 11-06-2013, 10:30 PM   #16
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I think you mean the Appalachian mountains.....
I don't remember the details of the flow bench....the data is in terms of flow above the benchmark which is an average of many stock VVT heads. I remember it was just a little better than 20% more flow than stock. I forgot the paper at the shop that did the flow bench.....pretty sure he recorded it in his book though. If not, I will pull the head and do it again when it is time to order cams....
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Old 11-16-2013, 06:45 PM   #17
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It has been a while.....I am finally starting to work on my car again. Here are a couple teaser pictures of what I did today.....

In an effort to continue with my copy of Soviet's awesomeness I wanted to use the LS truck coils. I welded 1/2" aluminum stand offs to the valve cover and tapped them M5X.80 so I can mount the coils with the same bolts that GM did. I had to mount them on the exhaust side and I will fab a heat shield to protect them. I also had to mount them aft of the plug holes to clear the factory strut tower. I also welded AN-10 bungs for an oil catch can. Will be traveling north next week and probably won't get to the dyno until the first week of December. Hoping to see 370 on the Mustang dyno.....



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EFR6258 on a VVT W PS/AC-20131116_164548.jpg   EFR6258 on a VVT W PS/AC-20131116_164621.jpg  
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Old 11-16-2013, 08:48 PM   #18
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Ahh love this car. Great build man, and great job on the DIY stuff. Really nice job.
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Old 11-16-2013, 09:30 PM   #19
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Thanks! After reading for two years what other on this site are doing I am trying to build the very best turbo setup I can. I look forward to seeing what "all of it" will produce on the dyno......
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Old 11-17-2013, 01:01 AM   #20
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if you have access to e85 this should produce some very impressive results. if not, water/meth whatever. should still be a beast
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