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Grapplers Fire Rebuild

Grappler

Grappler

Member
Update time again...

Well lets see I have gotten a bit more done since the last time I posted here.

Tapped and Threaded EGT Fitting




I started porting out the LIM after destroying several High speed cutoff discs hewing a rough shape out my dremel died...
So I took it to FNR and they are going to finish for me (thanks guys)



I Modified my S4 waste gate to fit the S5 turbo and it works !!!! this made me very happy a little snug but the actuator works fine and the movement of the flapper is not impeded that I can tell.

(I had a cold so don't laugh)

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I also before my dremel died cut up the CF Gauge holder I got from summit and made it so I could fit a 60mm gauge :D
I think I might place the gauge in the glove-box and open it when I need to tune since I am slightly leaning towards a sleeper look



Got my HKS Filter all mocked up onto the AFM and I do have a replacement element on the way its just taking forever to get here... good thing I bought 2



Turbo and Manifold all bolted up and looking amazing in the engine bay :D I still have to install all of the lines like oil and coolant feed and drain but its on the list of things to do still.



I also managed to find a rubber coupler to install a make shift TID 3" to 2" will work for now till I get something proper put in.



few other things as well I can't remember off hand or don't have pictures of but keep looking for updates.
 
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Grappler

Grappler

Member
Allright so its that lovely update time again

First thing I found out is Racing Beat resonator is not a direct Main cat replacement its about 3 inches too long for it which made a few headaches...
so the main cat is back on all the horsepower robbing goodness of it.
Second Thing is I found out how much of a pain it is going to be to drop the oil pan which is the main reason I didn't get to go to the auto x class this weekend :(
Third I found out the efan I had is bad so... either its back to the good old clutch fan or I find a new efan... which isn't a bad thing just means I have to more conservative with my IC piping.
Fourth thing SS line hurts the fingers a plenty wear gloves

Anyways on to the pics :D

Here is the Modified LIM I made took forever with a dremel.
I also put up a couple close ups of the port work.




Here is the SS parallel fuel system I have setup before its installed its -6an line running to the hard-lines
That red tube thing is a 40 micron fuel filter Surprisingly I only used about 10feet of SS line to make the fuel system.


And here we have it installed in the car that's an Aeromotive FPR mounted to the firewall and that blue vacuum line will be hooked up to the LIM Soon


Here we have the turbo mounted up properly with the main cat installed not the resonator...
I ended up blocking off the water cooling lines all it does it help cool down the turbo. So as long as I let it cool down properly i.e. let it sit for a few min at idle I should be good to go.



I finally have most of the wiring done in the engine bay I have rewired the FD alternator
to work in my FC and it may look shoddy but its hard to hook up 4 wires of totally different gauges together.
All that's left to to as far is wiring is concerned is hookup the A2w pump and fan to the electrical relay and from the relay the harness.
I need to mount the reservoir and pump first though :(
Now I have the UIM manifold and TB installed here I have hooked up a brand spanking new TPS (most expensive part of the car I swear)
I also hooked up the IAT sensor everything lines up with the fuel system so thats all good.



I started to run the IC piping and heres a nice picture of how the DSM bov is going to sit in the car.
Since I might have to reinstall the clutch fan I have figured out a strange way to route the IC piping if it works.



Last picture I promise for today Heres how the engine bay is sitting as of yesterday it looks good and I am happy I am getting so close to being done.
Its been hard to keep motivated to finish but my lovely assistant helps keep me going.



Ok I lied one more picture this one is of my lovely assistant helping me install a new filter element on my HKS filter :D



Things to do before its finished:
Tighten Downpipe nuts
Attach Oil feed line to the turbo
Tap Pan and attach oil drain.
Attach Fuel Feed line to the hardline
Remove old Fuel Filter
Mount A2w Resevoir
Mount and wire A2w Pump
Finish IC and IC pipe running
Run Vac line for boost sensor
Wire in Gauges

Start car
 
Grappler

Grappler

Member
Yeah... so more pictures

Current Photos before I left yesterday night.



IC piping as it sits right now I wish I had that efan working but $$$ is getting a little tight so this will have to do for now. Its not the best routing but it works still is a lot of bends though.




Mounted the resevoir finally :happydance: its going to sit like a modified Vmount setup I have seen a few people do this on rx7club forums they say it works great for them so who am I to argue. I am also going to mount a 7 inch fan to this thing to pull air from under the car. Maybe even rig up a scoop or something just ideas floating around for now though.



The Resevoir sits really well I had to bend a couple of the A/C hardlines a bit but its never really worked anyways so I am not too worried about it I need to grab another couple of things to totally secure it but for now its a good test fit.




Things Left to do

Mount and wire A2w Pump
Finish IC and IC pipe running
Wire In Gauges

Start Car
 
dmention7

dmention7

Hater
Man, that has to be some of the craziest charge pipe routing I've ever seen! But hey, functional is functional, right!
 
Grappler

Grappler

Member
well I couldn't help it but I redid the inter-cooler piping and found my leaky o ring that was making gas puddle under the car.

Much nicer now :D


This little bugger caused me all sorts of problems.

 
Grappler

Grappler

Member
Car has started just waiting for gas money :( (i.e. paycheck)
Adjust the idle
wire up gauges and get some tuning in

Then I am good to go :)
 
Grappler

Grappler

Member
So some of you guys know I took my car to MAP they did some awesome work on my car and found about a million and a half boost leaks that they fixed so it holds a proper idle.
They also found a few things that I need to fix like a motor mount that this whole time had been held on by a standard nut instead of metric so it was stripped out
and they fixed my oil drain so oil wasn't running out of my down pipe basically all the things i did wrong they fixed and they were awesome to deal with so huge shout out to them.

So thats why I haven't met you guys yet things are back on the to do list.... :(

:things to do:
Replace motormount
Replace leaky BOV/recirculate
Get Efan and optimise I/C piping.
 
Grappler

Grappler

Member
^Thanks and its crossed my mind more than a few times

Parts sitting in my room right now...

Huge Efan
Himni Racing Motor mounts slightly stiffer than stock but should be ok for DD
Greddy RS with Recirc supplies and flange
Greddy turbo timer
3" 90 degree coupler
-10 90 degree fitting for drain
Still not done ordering stuff :(

So I also recently realized why I hate buying things from ebay...



One on the left is the one I ordered one on the right I got for free from the guy that sold me the Greddy RS
Per the Ebay ad the one on the left is supposed to have the flange mounted parallel to the pipe...
The piping is meh at best its rolled, it has a seam line that runs down the bottom of the pipe
Whoever welded this did a terrible job its not flush what so ever with the piping and the flange is warped

serves me right for trying to save a couple bucks by ordering a pipe + flange instead of 2 couplings and t clamps... grrrr
 
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Grappler

Grappler

Member
PROGRESS!!!!!

Turbo drain 2.0


Turbo inlet duct 2.0 (now with recirculation fitting)


New I/c piping arrangement :D


Efan in place :D :D :D (ignore the untrimmed zipties)


Whats left
Wire Efan
Install Motor Mounts
Reinstall TID and recirculate

THEN ITS DONE!!!!
 
dmention7

dmention7

Hater
Out of curiosity where did you get the braided water lines and fittings for your heat exchanger? Those would be a nice visual upgrade for the black rubber stuff I've currently got.
 
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