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Hey man, just wanted to say that this thread is really cool. Happy to see you still here updating, sorry about the engine loss! Cool idea to check the rod length though.
Yeah, it will be a bit more than 'rods only' - forged pistons/rods/Boundary OP being the main ones, new turbo (probably Pulsar garrett clone) on a Kraken high mount, flat top, injectors and a new clutch. Looking for around 220rwkw, short of being a gearbox breaker!
In other news, I KNOW I have a set of the Sadfab bonnet louvres but I am buggered if I can find them... ... I reckon I am going to need them now.
Yes, that was part of my thinking. Also an obstruction though, I am banking on firstly the radiator has excess cooling capacity, and secondly that my ducting/sealing/venting pay dividends too. A set of Singular vents is being prepped for installation as we speak ....
However a new turbo and more heat generation might mean finding a Plan B, we will see
The block is back from the machine shop, no dramas there, as expected but you never know ...
Currently putting together the rest of the gear for assembly - Qmax reroute, flattop, Kraken manifold, etc etc. Looking at turbo options, Pulsar GT2860R Gen2 clone top of the list (it helps that stock available).
While moving the car I noticed that the front Billies need new seals too, wish I had seen that when I had the rears done. The front shocks are out, geeze they are crappy. The oil leak is pretty small, but it doesn't take much oil to collect the dust and crap from my dirt access road, and it is only going to get worse. Tomorrow I have booked out to dismantling them prior to delivering them to Heasmans for new shaft seals, a la the rears - they will also get the MCA condoms to stave off a repeat, the rears are already sporting theirs.
While in there I noticed that one of my ELBJs has a torn boot, that will need fixing while the front end is apart.
Dismantled the flattop IM today, dragged out the die grinder and attacked the TB mount. Pretty pleased, the step from the Junk2 TB has gone and it is a decent taper into the IM body. Between the IM entry flowing better, and the flattop's better overall performance, I am hoping for good things when installed. IM obviously came off a sick engine, lots of oil caked inside. My little parts washer struggled and failed to properly clean it, looks like I need to hit it with a more potent solvent as I am nervous about filings from the grinder ending up in the engine, so all that sticky residue has to go, and then it has to get a thorough clean. Colour me paranoid, but after I have done my best I think I'll get mania to run it through their parts washer as insurance.
I need to get this done ASAP as I want to get the next box of engine bits to Mania next week so he can get into the reassembly of the engine, dropping the shocks off as well. Busy few days ahead.
... and doing prep work like porting the Junk2 TB to the new (old) flat top IM. Thanks Lokiel for the tips on cleaning up the IM..
Well, yes, thanks for that tip Lokiel, but the presence of the bosses of which you spoke (and photographed) was notable for their entire absence in mine. I meant to take a photo, but now the box of bits is with Mania for the reassembly, but I could see the circles in the surface of the casting, but they were either flush, or even a little recessed. It looks like the plugs they put in those holes in the molds are quite variable in how far into the mold they sit.
Currently pulling the ELBJs off to replace the rubber boots, both of which have split. If I can't replace the boots the stockers go back on, as I am hearing that the current batch of Bauer ELBJs have a life measured in hours, and that may be generous. Front shocks are being rebuilt as I type this. As soon as the weather breaks with a bit of sun, I'll start the installation of the hood vents.
My planned trip to Cairns via Cunnamulla (highlight: dinosaur museum and stampede at Winton) by caravan with my daughter and the grandies is off (late delivery of the new van) so they are driving straight to Cairns - more time to work on the car!! But I was looking forward to that trip ...
... and how we got here, the latest acquisitions for the Black Museum!
The ball joints in the front are done, the shocks are done, so the front end can go back together. The car has been booked in for early August for installation.
The light at the end of the tunnel is getting brighter ...
Last edited by Gee Emm; 07-21-2023 at 08:18 PM.
Reason: spelling
I have a deadline, though maybe able to be fudged a little: car is currently out of rego, and needs to be back all legal before early September. Reason being if the rego lapses after three months, it needs a more detailed pre-rego inspection. Between the aftermarket ecu and the new turbo, that could complicate things, worst case requiring engineering (ie an authorised motor engineer has to sign it off, which might (unlikely, but still ...) also involve emissions testing). Planning to avoid that, for the cost, inconvenience and delay in getting back behind the wheel. So the hammer is definitely down ...
Yeah, I'm going to mount those rods and display them. I've got a broken suspension arm from a Fiat 500, the top of a piston that got hammered by the head of a broken valve at Eastern Creek, the mudguard from the wreck of the original GreenMachine which a mate stickered up with my sub-3mins Bathurst time ... probably a few more that I have accumulated over the decades! Also got my brother's FF steering wheel, bent in a 'U' after he put it head-on into the sleepers at Amaroo with a stuck throttle - geeze I might have to build another shed!!
Yeah, it's a Gen2 2860r china clone, No, you didn't miss it, Mania's go-to brand which I don't have to hand.
It was a choice between those two, but went Mania recommendation because they are doing all the work - if anything goes wrong, there no room for that 'but that is what you wanted, so it's on you ...' stuffing around. I figure since they have had a good run with these it was a toss-up, as likely to have a problem with one as with the other. They are currently tracking a car with this turbo getting results and having no issues.
Just come in from buttoning up the front end. The front Bilstein PSS9s went in for new top seals (they were starting to leak), when they opened them up they needed a total refresh inside, only thing not replaced was the body and the shaft, and the shaft got a polish along the way! I only hope they got the valving right, they assured me they put in what came out, but they didn't dyno them unfortunately.
Also new are the lower BJs (stock), one new tie rod end and one new upper BJ. It will need a wheel alignment as it was wearing ELBJs before, the rubber boots split and replacement ELBJs have a very short life apparently. It is still on the axle stands, but will come down tomorrow as soon as I can get the jack out to it.
Then it's off to Mania on Monday to have the newly rebuilt engine installed. Hopefully back on the road around the end of the month - happy days are coming!
Sorry if I missed it, but what PSR turbo did you end up going with? I see it's a 5-bolt exhaust flange so I'm guessing the Gen 2 2860R?
Yes 2867R gen2.
Turns out I lied - he didn't use their usual brand, but went for the Pulsar, it was a bit cheaper too. David said that the casting marks on the exhaust housing seemed identical, so he thinks both came out of the same factory. No surprise there.
Trailered the car down to Sydney this afternoon, getting to the business end of the operation now. Couple of weeks, and ...
Well, progress. The car has been running in on the dyno this week, next week a final preliminary tune. I want to get it back, get the radiator properly sealed, put in the bonnet vents, things like that before I start shooting for serious power. Just six sleeps to go ...
In other news, the hoist is up, and now fully functional. Much drama there, plugged it in, pushed the green button - nothing, nada, just the sounds of silence. Checked the wiring, all good, looked inside the control box - promptly shut it again, that is beyond my pay grade, far too many wires! After rechecking all the new wiring, I gave up and called Warren the Hoist Whisperer. Warren rocks up a few days later, has a look around, I hear a click, and the next thing is the hoist is working. FMD! I was pretty pleased, a note changed hands, and he was on his way. I was worried a new pump would be needed, this cost me less than 10% of the pump price. Next morning I go down, hoist won't work - cue incredulous despair! Long story short, I discovered what caused the click when WtHW got it working the previous evening - the emergency stop button can be rotated to fix it in position when pressed. I still need to finalise the balancing of the arms, one is 10mm higher than the other, but that is trivial, and I need to clear out all the crap that has accumulated so I can get a car in there and work on it..
I'm concerned that they DIDN'T shield the A/C Receiver/Drier cannister at all and the suction hose from the evaporator is right next to the hot turbo exhaust housing.
Unfortunately when you wrap the hose in anything, it'll touch the housing :(
You might want to consider pulling out the A/C fuse before testing "in anger", then look at the hose to see if it's melting before putting the fuse back in.
I moved my cannister and routed the suction hose OVER top, cladding it in heat shield to avoid these issues:
I have told them to forget the catch tank and the airbox, I'll fix those when it gets home. I am fully expecting to have an issue with the A/C, and that won't matter, as I need to make a change to the patch harness (I think) but as it is non-functional now I can just remove those bits and have them re-made, at the same time get the electrical/ECU side sorted, then finally re-gas it. Yes, that location Lachy used is what I had in mind for the relocation, I hadn't looked closely at his pipe routing before but that seems pretty neat and out of the way too. My Nautilus air horn will need to be moved but that is just electrical wires so NBD. Your location is not somewhere I have considered, and I'll have a closer look at that when the car returns. Either way I think that if I am going to move one pipe I'll do both probably along Lachy's routing.
04-25-2023, 08:48 PM
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... I reckon I am going to need them now.
I meant to take a photo, but now the box of bits is with Mania for the reassembly, but I could see the circles in the surface of the casting, but they were either flush, or even a little recessed. It looks like the plugs they put in those holes in the molds are quite variable in how far into the mold they sit.
- happy days are coming!
