Tacoma Noob Project
 

Hello everybody,

I had to post the first 4 days together, but from now on it will be updated daily as I go.

Incase someone didnt read my Intro post here are my quallifications:

Experience19 year army veteran, 12 of those years as a helicopter engine mechanic (turbo prop engine not reciprocal), and about 25+ years of general wrench turning.

Facility Auto Skill Center Ft Lewis, Wa. A place provided by the Army for the do it yourself warriors, complete with all the tools and gizmos necessary to complete almost any job.

So far this is whats been done.

Day 0: Picked up and drove car from Orlando to Tacoma (4867 miles to include a detour in Vegas) May 25

Day 1: Shop was close due to inventory and annual fire inspection. So, I took the car home, got an electrical sander and empty 2 six packs. Oh yeah I did some sanding between Beers. June 23

Day 2: Drove 2hrs pick up a hard top. (craightlist add) Drove back only had time to perfom a compression test. 170-170-175-170, Not Bad for a 19 year old engine w/230K+. June 24

Day 3: I had previously picked up a RE-1 Body kit from a guy that attempted to installed himself and Fail ($200). Since I got no more space in my storage facility, and did not want any one triping over it and breaking it, I went ahead and "dry-fit" installed. It needs lots of work since the original guy damn near destroy it. June 25

Day 4: Engine & Tranny are out of the car. I was unnaware that the flywheel in this car was so heavy. No major Issues, but I am getting old. It took me almost 5 hrs to get that sucker out. June 26

Sorry about the low quality pictures, but the cellphone is all I got.

Please share your experiences with me, and I accept constructive Critisism...but I dont like to be troubleshot, I am too old for that shit.

Stick with me to the end...I only got 7 weeks to finish this up!!!

Do you have any pictures of the front bumper? Doesn't look too ricey from the side but I might loose the side skirts if I were you.

It actualy crossed my mind, but I am going to remove them, prep the underside, and then heat and blend them into the car. Its all about the unique thing, different from others.

All suggestions are greatly appreciated.

I am very interested in hearing from people that are running bigger valves (1mm over), and Cams (I am thinking 264*).

Also, I have worked in many engines before, but as we all know all engines are unique. I want to hear about the "watch out" things and the pros and cons of anything.

I am doing my research here, but any contribution will be greatly appreciated.

Thanks

The FAQ section will pretty much have all the "watch outs" for you. As well as pretty much all info to get you started with boost.

Will you be rebuilding the engine before boost? cause if you're not why do the cams and oversized valves? I say do all the standard maintenance, get that sucker up to shape maint wise, then start piecing together your own kit. Looks like you have the brains and experience to do it without many problems.

If you're pressed for time though looks like a starter kit from BEGi or FM would get you started REAL quick, then you can upgrade later.

Quite a few of us Army guys on here as well as a few Marines, Squids and yes even cChari Force guys as well (although that may have been covered in your intro thread that I'm too lazy to go hunt down :giggle:)

What are your final plans for the car after your 7 week build time?

This will be a total engine Rebuild. I have been looking at those kit options (Because of the time). Engine should be completly disassemble today.

Will post pic tonight.

I got to drop the car at the prot of Tacoma NLT 15 AUG. I dont report to Hohenfels til mid October, so I guess I'll be hanging around in Munchen (October Fest) till they run out of Brats and Beer!!!

Any clubs or groups up there near the "Rock"? Keep in touch brother, will meet soon!

Awesome, I'll be training out in Hohenfels in October, I think your going to have a hard time running Munich out of Beer and Brats, there's plenty of good beer all over the place in Germany though, more than just the crap you see everywhere, go check out my posts in the "Beer of the Day" thread.

Have you been stationed in Germany before? This is my first duty station so I'm still nice and fresh in the Army, haha. No clubs to speak of here, I'm riding around in a '90 BMW with no more miata to speak of, probably won't have another one until I'm back in the states. Good luck on your project for sure!

I Know all about the Beer and Brats...but I will definatly attempt to put a dent on one of the keegs there!!! :bowrofl:

I am an old dog, been to Germany a few time (14 years all together). Bounce around Wiesbaden, Grafenwohr, Ansbach, Illesheim. (also speak the local lingo)

I was asking about car clubs(i alreday know where to party)

as for the car; a total rebuild (inside and out). For the turbo, ah...no more than a 2871 or equivalent. I am not planing on racing it or burning tires at every street lilght. Just something nice that turns heads and can keep up on A6 without getting flash-off the left lane.

So was I :noob:. :giggle:

Day 5: Got up late, was dragging ass all day. Not much accomplished. June 27

- Dissasemble engine. All pistons and Cylinders measurements and clearances are within book standard
- Quick clean up.
- Lable all parts.
- Removed Seats.
- Removed Center Console and Intrument panel (what was left of it)

Shop is closed Mon and Tue. Will take engine & head to machine shop this week (whenever pistons and valeves get deliver)

Gotta love those Army service centers. I used the one at Goodfellow quite a bit.

Welcome to mt.net

Day 6: Shop is closed, so I brought a few parts home and did my best.

Setback!!! Pistons and rods came in, but they are the wrong size. Call the guy, lots of blah blah, It will be two weeks before I get the correct ones. (Putana di merda)

Seat covers are decent quality $120 (ebay).
Glow gauges $16 (Dont think I will keep them)
Pretty up the Valve cover $12 (including a sixpack)

Day 7 Not much got done.

This is starting to look like the classic "ship Wright Disease project"

Cant lose motivation! Time to pull and dust off the old bottle of Johnny Walker blue I have hidden in a foot locker.

After pulling the Carpet and Dash I realize that this look a lot worse that what I initialy expected. Hole on the floor board, cables fried, tons of rust.

BTW, I have search all of the sites around with no luck. Can anyone here hook me up with a complete Torsen set up? PM me please. Need it before the end of the month.

Day 8: Unable to accomplish Jack. I am sick as a dog, and starting to get frustrated. Just did some major cleaning, patch the hole on the floor board, and cut the holes for the speakers (Hakuna style).

My normal work load is getting on the way, and to top it off I get to watch the "extra duty kids" all next week (stupid pot-heads).

No pictures today.

P.S. I attempted to Pm Braineak for an MS, but he havent responded (I am sure the man is busy). Is anyone out here willing to build one please PM me. I dont have the time nor the tools to properly do it. My hands shake too much and my eye sight is suspect.

Contact Wayne_Curr on this board, he's less busy than Braineack and will build you an MS for cheap.

Glad you dove into the cleanup of that interior without giving up, a lot of people can get too frustrated to continue at that point. Take a pressure washer to the carpet if you have it, then lay it out to dry in this incredibly hot weather we're having.

The interior was taken care off. I took a grinder with a wire brush to it, then welded a sheet metal patch, cover the complete bottom floor with fiberglass resin, and to top it off painted over it with Rust Oleum. Overkill, yes it was, but I garantee you that floor will last longer than the whole car (it will also help with sound suppression.

Thanks for the contact Curly.

I'll PM him right away.

Day 9: July 14 Done with the baby sitting of stupid GI's. Got to work on the car for a few hours.
- Sound prof the floor, back panel and rear deck.
- Ran all wiring for the stereo system.
Day 10: July 15

- Put dash back in, the carpet, soft top, and did some spark chasing to fix some minor issues.

Day 11: July 16

- Ceramic coated the piston crowns and teflon the skirts and lifters
- Pick up engine block and head from Machine shop.
- #4 Oil Jet bolt broke while torking.

Notes:

- This engine was originally desing for the mazda 323 GTX, which is a Turbo engine. The stock pistons can withstand around to 30 PSI, forge pistons around 42PSI, but they need tapering of the cylinder wall in order to better protect and keep piston slap to a minimum.
- While doing research I noted that individuals that use forge pistons rebuild their engines more often than the ones that keep the regular pistons.
- I originally wanted to oversize the cylinders and put wiseco pistons, but since I am not going to run this car on the track and most likely keep it below 12 PSI of boost, I decided to keep it stock.
- I am still upgrading to 256* cams and 1mm oversize valves. I understand this is going to be a headeck when it comes time to do some tunning, but I have already purchased this and I am not going to stare at them or keep them around as paperweights.
- I still got tons of work to do. I just hope shits stops breaking and setting me back.

If I am writing about something that doesnt make any sence by all means drop a line and lets disscuse it. I have never claimed to be a genious...just a sick nut that love turning wrenches!!

Don't worry about pistons, as you have already discovered, stock ones are decent for a turbo setup. Before you ever reach 30psi though, no matter the turbo, you WILL break your differential, transmission, and bend your rods. More or less in that order. It's a flip of the coin whether you bend the rods or break the transmission first.

I'm just reading your last post, do you have any idea what manifold, turbo, DP, and engine management you'll be running?

I finally found a Torsen 3.9, it should be coming in week after next. I am also looking for a better tranny, but lets see what happens.

Today I should have my injectors and the DIYPNP coming in the Mail. I told Wayne that I will take a look at it first, and if I see that its out of my leage I will drop it off by his place and let him build it for me.

As far as the Turbo stuff, I got a GT2560, LM1 wideband Sensor, DIYPNP, DW 600cc injectors, 255lph fuel pump, FM fuel rail, Six puck clutch and 13lbs Flywheel, a cast manifold and cheap DP from EBAY, but thats just till I get to Germany and have time to make a decent one together with downpipe.

I need to find that oil jet bolt today.

Day 12: July 17: Spent all morning running around trying to fing that Oil Jet Bolt, and no luck. Finally broke down and call the dealership...$25 for a fucking bolt!!! It'll be here on thursday.

Was only able to work on the car for 3 hours

- Remove entire front suspension system
- Remove wheel hubs
- Repalce Bolt joints (lower) and Boots (upper)
- Remove and replace inner and outer tie rods

Waiting on bushings to complete the job, should be here on tuesday. Tomorrow I am going after the rear subframe and differential.

DIYPNP is here, lets see if I can do this thing.

Day 13: July 18

Many bolts seize and frozen in the rear suspension system, had to cut a few of them. I will spend the next two days fabricating new bolts, cleaning and replacing the bushings.

Still reading the DIYPNP documentation.

My supplier failed me, I went to pick it up today and the "Garret 2560" turned out to be a turbo for a diesel application...that thing was huge!!! I am glad I did my reading here and save myself the embarrasment and $250. So fuck it, I am going Churbo for the initial set up, will upgrade when I get to Germany.

This project is turning into a real nightmare...and the clock is ticking.

Nice so far. It looks like your making some good progress despite the setbacks. I really like what you did with the pistons and lifters.Don't cook them for too long they'll be dry and not very tender.:giggle: I'm anxious to find out how they work for you.

I would be suspicious about the 30 psi on stock pistons. At 16-17 psi mine decided it didn't need the ring land on the #2 piston anymore. This was of course before my stupid ass had an intercooler.:facepalm:

The high silicon content makes them brittle. The Wiseco is kind of the best of both worlds. It's a very low silicon forging which allows one to run a tighter piston to wall clearance as opposed to one carved out of an aluminum billet like the JEs. In any event, at 12 psi the stock ones should be fine. With proper intercooling and good fuel, you should be able to squeeze more out of them.

Like Curly said, there will be plenty of other things that get pushed past their limit anyhow. My poor diff feels like it has about an 1/8" of backlash in it from running 20 psi on it. I just love stress testing my parts.:bowrofl:

Looks like your on your way to a fun ride. Best of luck with it!

I've done the ceramic coating before. My brother had an MR2 and after 2 years we change the head gasket and the piston crowns were almost perfectly clean. The ceramic coating prevents the formation of gunk on the pistons (seen this first hand). The teflon (dry lubricant) keeps the skirts nice and moist .

I dont thrust the 30PSI thing either. I beleive in substracting 40% off manufacturer limits just to be safe.

Thanks, this Forum its whats keeping me motivated.

Day 14 July 21 Had some good progress today:

- Installed new Radiator
- Made Brakets and installed IC (not the pipes)
- Replaced Fuel pump
- Installed crankshfat and bearings
- Replaced steering wheel

Wasted some time helping the guys next to me. Their engine stand took a nose-dive with the engine on it. They are building sleeper trucks (old Ford F-100 and F-150 with a 454s in it).

I am hoping to have the engine in the car by Saturday evening.

Still waiting for Diff, manifold, and bushings.

I got 1 month till completion. Then I fly to the land of Boobs, Beer and Bratwurst!!!

News flash. 7.5 liter engined are heavy. Glad Youre chipping away at progress. What wheel did you go with?

I just got a cheap ($20) wheel from a local swap meet market here in Tacoma.

Day 15 & 16 July 24-25

Saturday- Spend all day wiring Gauges (Oil Temp, Bost, AFM). My big monkey hands dont help much when it comes to small tight places.

Sunday - The engine is completly put tougether, but I was unable to put it in the car since I still missing the bolt for the oil jet.

MAZMART failed me; my diff is not here yet!!!
Mazda parts center screw me; they forgot to order the bolt twice the same week.

Thanks Travis, I got the injectors right on time.

Wednesday and Thrusday are going to be knockle buster. Complete suspension goes back in the car.

The way this is going I am going to have to put this car on a boat the way it is and finish this project in Germany.

Which "oil jet" bolt are you missing? Is this the oil squirter bold in under the cylinder bores? I have tons of these if you need them.

Yeah thats the one...PM sent

Day 17: Jul 28 Started changing the bushings on thge front end. I wasnt able to finish. This things were attached for dear life.

Day 18: 29 July Completed the front bushings. Started the rear end and my tools had enough, they busted up halfway thru the job. I was too fustrated and tired to continue.

Day 19: July 30 My hands are in pain from all them bushings (I'll finish them up next week)
Ran around got some more tools.
Mounted the intake Mani and Injectors
Drilled Hole in Oil Pan
Pretty much a wasted Day

Day 20 : July 31 Got the Bolts From Wayne_Curr (thanks Brother)
Re-checked all of my torques
Installed Oil Pan
Installed Flywheel & Clutch Kit
Installed Transmission

Day 21: Aug 1 Put engine in Car!!! That took me 3 hrs since I had to do it alone.
Started Cutting pipes for the DP

This was a terrible week to get anything done. I spent a lot of time working and at the end of each day I felt that I got nothing done. I am starting to run short on patience, time and money.


So here I am going to use my freebe stupid question.

Below is a picture of the vaccum diagram. Yes I have read, and done my research, But I am still confuse.

I want to connect these thing the right way the first time.

Can someone please conect the dots?

I will be very Greatfull

I got the DIYPNP completed. I was able to flash the firmware , but it will not connect to Tuner Studio (Comp Port issue). The Mega Tune program does recognize it. I have not loaded anything to it other than the firmware using a 12v 500ma plug at the house.

I have tried everything that I know on the computer side with no luck. I will not be able to test it in the car for a few days. I followed the instructions to the letter from the DIYPNP site. I have checked all connections and jumpers on the boards and everything is soldered right. I have also search this site, and Google for answers with no luck.

Any Ideas?


BTW I got the vaccuum thing figured out from my previous post

Give Mannheim a nod for me if you pass by... some good memories from there... and some drunken-hazy-not-so-good ones too - I think :friday:
In for seeing how this plays out, keep it coming.

If you had to buy a usb to serial adapter to connect to the PNP, you'll have to install software for it before your laptop and PNP talk. Thought I'd mention it just in case...

Hey everyone,

Just in case anyone thought that I failed, here is the latest update.

The last two weeks have been hell on me. Trying to clear the post (Army thing), work on the car, and illnesses, I have some progress and set backs.

After putting the engine back in the car and attempting to build oil pressure, I came to find out I had bought the wrong oil pump. Since the last one was still in good shape engine came out of the car and oil pump was swapped.

Then came the fuel pressure nightmare. After many hours of trouble shooting it came to be a bad ground (actually a lose cable)

After all that corrected and done (fuel pressurize, and oil pressure started) I hooked up all electrical, and vacuum hoses and gave her a crank.

SHE IS ALIVE!!!...ALIVE on the very first crank. I almost had a tear come out of my eyes (maybe because I rubbed my eyes after bleeding the brakes)

She is far from being completed (still got to do all the body work and fine tuning), but I am out of time. By the end of this week she will be taken to the ports and shipped to Germany. So far I have spend well over $4k on the car, and she is still not even halfway done.

Here are some pics, but please take it easy...like I said she is far from being completed.

Thanks to those who kept up and gave me some motivation. Although this threat might die for a while. I will resurrected once I feel it is necessary to post something entertaining.

Good Luck to everyone. Catch you all later!

P.S WAYNE_CURR, don't think I have forgotten about you! Once I get to Germany I will payback that favor.