My S13 stage 3 project story

[igralec]

Better late than never i guess. Hope this isn't againt the projects section rules, as the project is almost finished (if you can ever say that) and this will be more of a review of everything done so far...
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So, in march 2005 i was buying my first car. And i wanted a turbocharged car. I was after a Punto GT first but was beaten to it, then almost bought an Aprilia RS250 (i have a thing for bikes, owned an RS50), but my neighbour spotted the S13 ad and it looked in a good condition compared to the others that were for sale at that time. So we went to check the car out and i ended buying it since it was something special when i first saw it.

The car was 1990 "facelift look" prefacelift completely standard apart from a big single exit backbox. It had 149900ish km and a fecked turbo, which i found out after i bought it (the guy i bought it from said he might have overfilled the oil and that's causing the smoke on idle... yeah right).

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It was a bit embarrising at the lights when the car went into smokescreen mode, but it was fun when moving.
In may 2005 i bought a bailey DV off here, it was my first "mod". A couple of weeks later i got a low mileage T25 from a mate and it was time to have the turbo and all the gaskets changed. At last i could drive around without the gasket blowing noise and the dreaded blue smoke.

A month later got the backbox replaced with the standard one that came with the car... it was a bit to loud for my taste, so i sold it.

In august i fitted a boost gauge, twin a-pillar pod and K&N 57i kit. The car felt more responsive on throttle and the air sucking noise from the new filter was sweet.

http://i150.photobucket.com/albums/s81/igralec/project-thread/th_8.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/8.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_7.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/7.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_6.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/6.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_5.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/5.jpg)

In november i got a first taste of snow + RWD and it was really fun. Spent around 2 hours on a pretty big local parking lot playing around and doing circles around shopping carts, joined by random cars and even the police who joined for some "handbrake training".
A few weeks before Christmas the S13 gave me a present - a nice big end rattle. I did around 500km with the big ends going, but was lucky the crank wasn't damaged. In january 06, big ends were replaced by a mate, oil changed, read brake pads changed and BCPR6ES fitted.

February 06 was the month when it all started. I bought a bren device and a stage 1 chip from Jez... got both fitted, went for a test run... 1.6 bar. Eventually set the bren device to 1.1 bar and was really impressed at the difference a chip and raised boost made. The feeling when you first drive the car with some new parts fitted is amazing... and in long term bad for your bank account balance.

http://i150.photobucket.com/albums/s81/igralec/project-thread/th_12.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/12.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_11.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/11.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_10.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/10.jpg)

Next month a fitted a grade colder plugs, BCPR7ES and decided to change the boost gauge for a smoked one and buy a matching oil temp gauge.

In july i bought a 2nd hand Apex FMIC kit (3" core) and got it fitted by a mate. Since the Bailey DV was on the cold pipe and i got a bling cold pipe with the FMIC, i decided to sell the BOV. The battery was moved to the boot, washer bottle replaced with a prefacelift one, front bumper cut a little to allow space for the FMIC. I got a 0.1 bar boost increase from the FMIC and when adjusted back to 1.1 bar, it was a bit quicker and came onto boost a bit harder.
Before i got the FMIC fitted, the standard clutch started slipping, so i got another 2nd hand standard clutch and had it refurbed and uprated by a local company.

http://i150.photobucket.com/albums/s81/igralec/project-thread/th_16.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/16.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_15.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/15.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_14.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/14.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_13.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/13.jpg)

It was time to have the car dynoed, with all the stage 1 mods, 1.1 bar and a standard non-cat exhaust. Result: 218.4HP and 277NM

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[igralec]

In the next couple of weeks i bought an Apex rear strut brace and a HKS SSQV. In november i got a custom made turboback exhaust made by a guy who owns a low 12s multiple drag race winning 500-600hp SR20DET powered 100NX. The guy is 20 or 21 years old and makes exhausts and manifolds for rally cars and other big projects in his spare time. Exhaust spec is 80mm elbow, 70mm straight pipe system with a standard looking backbox... the results were amazing, full boost a couple of hundred RPM lower, nice spooling sound at low revs and boost increase from 1.1 to 1.3 bar. The down side was it was a bit loud when i came home, got a headache during the 150km journey home but luckily had no problems with the neighbours since then.

http://i150.photobucket.com/albums/s81/igralec/project-thread/th_20.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/20.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_19.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/19.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_18.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/18.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_17.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/17.jpg)

Fitted the walbro fuel pump... about time too. I knew i reached the limit of the T25 and stage 1, so i slowly started preparing for stage 2 and an engine rebuild just to be safe. But first got the Apex shortshifter in december, very nice bit of kit except for the rattle on idle (release bearing vibration passed onto the gearknob) and a rattle at high revs. Since i fitted the shortshift from inside the car, i couldn't get the front 2 bolts back in and been without them ever since. Oh yeah, got an autogauge oil pressure gauge, that looked the same as the FK smoked ones too.

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January 07 was the month when stage 2 plans really got underway and i kind off decided that this would be enough in terms of tuning. I bought a 2nd hand T28 with 55k miles off here, braided turbo hoses from hosesolutions and turbo gaskets + Z32 fuel filter from apex.

http://i150.photobucket.com/albums/s81/igralec/project-thread/th_23.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/23.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_22.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/22.jpg) http://i150.photobucket.com/albums/s81/igralec/project-thread/th_21.jpg (http://i150.photobucket.com/albums/s81/igralec/project-thread/21.jpg)

February 07: disaster! The oil light lit up a couple of times and i put it down to the sensor playing up... boy was i wrong. On a sunday drive i noticed the oil light coming on after heavy braking and soon the big ends started rattling for the 2nd time (knew what it was straigh away). I put 1 liter of oil in which stopped the oil light from coming on and the rattle got quieter, but it was too late. Hoping to prevent damage to the mains and crank, i parked the car for almost a month until my mate got the space to park my car on his driveway (he was doing the rebuild as he built up a CA before).

I knew i wasn't going to get away with just the big ends this time. When he removed the engine from the car and stripped it, it was clear the crank had been damaged and the main bearings totally fecked, big ends to obut not so bad. The reason for all this were (apart from me being a numpty and not checking oil propely when the lifters started to get loud) scored cylinders, aparrently i bought the car like that and was usings a lot of oil. I had covered only 13.000km since i bought the car at that point.

The block and crank were taken to a machine shop where it turned out the crank has already been regrinded once and the local nissan dealer said there were no bearings for a 2x ground crank. The block had also been honed before, so there was no chance to use the standard pistons which were in good nick. I got another crank from a mate who had a spare engine, and my mate ordered 1mm oversize JE forged pistons from the states. From april to may, money just flew from my bank account. New cambelt and tensioners, complete engine gasket set, MHG, new oil pump, new water pump, new main and big end bearings... Ouch. In the mean time, i bought some stuff that would prevent me from killing myself with stage 2. EBC 280mm grooved & drilled front discs (got the facelift caliper carriers back in october), RedStuff front pads, EBC plain rear discs, Blackstuff rear pads, Apex front strut brace.

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Sadly there are no pictures of the rebuild, i was without the car and couldn't really go to see how things were going too often. And when i did, i forgot to bring the camera and take pics.
In mid May the car started up for the first time and around two weeks later i got it back. Since i sold the HD stage 1 chip, i had to borrow a ND chip to run the engine in at 0.7 bar which was the min boost the ND adjustable actuator could set (and as i later found out, it wouldn't go higher, dodgy spring). I spent the end of may and beginning of june driving around to run the engine in. During that time the clutch decided to start slipping, which was a bit odd for 0.7 bar which was less HP than on the T25 @ 1.3 bar. I eventualy bought a stage 2 chip from Jez and borrowed a bren device from a mate, so i could run 1.1 bar. Also got a pair of quite rare Nismo tension rods, made quite a difference to steering and going over bumps in the road.

As the clutch was still slipping badly, could barely get over 120km/h (but was fine in the rain), i was really frustrated since i spent a lot of money on the rebuild and stage 2 parts and couldn't get the most out of it. The T28 turned out to be a dodgy one too as it burned oil a lot, didn't smoke but sprayed oil out the exhaust. Luckly i noticed that and started keeping an eye on oil level... for obvious reasons. After a burntout while the clutch was slipping, i barely made it home and after that, it started working as it should. So it was time to get the car dynoed again, this time full stage 2 but only 1 bar (the turbo had good and bad days, boost went up and down in a matter of minutes). Result: 268.8HP & 313NM @ 1 bar.

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400km's later, after filming the stage 2 compilation video, i noticed blue smoke from the exhaust on boost, had to abort a 0-160km/h run when i noticed a blueish fog on the rearview mirror. Upon opening the bonnet, i was greated by oil sprayed from the SSQV. All the pipes were full of oil too. When i wanted to go for a test drive, i started up the car and in less than 5s there was smoke everywhere. And I thought the T25 that was on the car when i bought it was bad... RIP T28.
Lesson: even if it's a low mileage turbo from a 99 s14a, it can be fecked if it was ran on 1 bar for half its mileage...

As i mentioned earlier, i wasn't planning to go above stage 2, but changed my mind and planned stage 3 for 2008 and slowly started gathering parts... when the T28 died, i already had the 444cc injectors and Z32 AFM at home... wasn't long until i received a Z32 K&N filter with the adapter to fit the AFM and found a GT28R with around 1000km in the for sale section (my 2nd home). While waiting for the turbo to arrive, i fitted and connected the Z32 AFM to the loom and managed to get the standard intake pipe onto it using boiling water, sweat and a lava lamp top cone thingy.

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[JaPPster]

Nice contribute, let me mention one little fact, that this particular S13, is the fastest S13 in the country:eek:

carry on :D

[Nis]

What does it do on the quarter?

Ivan

[igralec]

it's the fastest because there are only between 10-15 S13's in the country and most of them are not drivable, others stock and a couple of stage 2 examples. It's no silly power example or anything shocking for your standards :)
Couldn't compete in a drag race event this year so god knows what 1/4 mile time it does, but will probably be low 13s with LSD, proper tyres and some basic weight reduction (rear seats, spare wheel, i'm a pretty good weight reduction myself :D ).

[igralec]

When the turbo arrived it was time to get the dead T28 off and replace it with the GT28R (aka GT2560R aka S15 T28BB turbo). Since the car wasn't going anywhere, it had to be done infront of the house. The manifold and turbo were off in a couple of hours with the help of a mate, i then fitted the GT28R onto the manifold and put a new spring into the ND actuator. The turbo core had to be rotated a bit for the oil drain and also the compressor housing because the actuator arm was a bit off. When it was all done, I made a stupid mistake and shortened the intake flange by around 3cm. But more about that in the end since it's a present problem, not a big deal but unpleasant...

The manifold and turbo assembly with braided water hoses (no, they weren't fitted when the T28 went on) were refitted in around an hour, the braided oil feed pipe couldn't be fitted because i didn't get the banjo bolt with the hoses and the original oil feed pipe is the prefacelift one that screws onto the turbo directly. I wasn't very happy reusing the 17 year old oil feed and although it's not blocked, bent or damaged, replacing it with the braided hose is one of the top priorities. When everything was done, i had to wait for the HD stage 3 chip to arrive. Due to the postal strikes, it took a while for it to get here, but eventualy it did turn up and i replaced the stage 2 chip with it. Fitted the 444cc injectors and that was that. Stage 3 complete.

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After the post turbo change procedure, it was time for a test drive. The actuator had been set to 0.8 bar as i didn't really bother shortening the arm when the turbo was off the car. I was really suprised at the spool up of the GT28R compared to the T28, it was somewhere between the T25 and T28, but closer to the T25. And 0.8 bar with it was noticably quicker than with the T28. I refitted the bren device which added 0.2 bar and at 1.1 bar the turbo really came alive. Then i got round to adjusting the actuator, shortened the arm and went for a test drive. With the bren device still on and a cold evening, i got 1.5 bar which was silly fast to say the least. Could smell the tyres burning when boosting it in 2nd. After removing the bren device, boost was set to desired 1.25 bar in 4th and 1.3ish bar in 5th above 6000rpm.
The 444s improved throttle response and surely gave a torque boost as the car pulled harder from low revs than before, but i'm yet to get the car dynoed.

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So, this is the story of my car from when i bought it until now. I'd like to point out i'm one of the (probably rare) people who tune the car first, and then take care of the suspension, wheels and exterior in general. After 2,5 years the car looks just as it looked when i bought it, no sign of 5000 pounds spent on it. I know it needs lowering, bigger wheels, spacers, etc.

Plans for this winter are:

- Sort out the intake sucking shut problem, it's annoying and i can't get the car dynoed. I will be sorted by getting another intake flange made, 3cm longer just like it was before i shortened it. The problem is i have a metal pipe in between the top and bottom springless rubber elbows and i reckon the extra 3cm created enough gap to suck shut at around 5500 RPM when the rubber heats up.
- Sort out the vacumm hoses, currently using a thin wall water hoses that almost melt and flatten above the exhaust manifold and near the intake manifold.
- Get the banjo bolt and fit the braided oil feed... this is my 4th turbo and i really hope it's the last
- Get the LSD fitted, i've had it in the garage since july... though i'd have it fitted before snow, but i don't think that will happen. Yes, stage 3 and open diff. And standard suspension and 195/55/15 winter tyres
- Oil change, from Valvoline Durablend to Motul 300V
- Try not to crash

Plans for spring:

- Get a set of lowering springs and use them with the standards shocks. It's more for the looks as i don't drift and do trackdays so don't need a hardcore setup.
- Get some 17'' wheels, 5-spoke, wide enough to fit 225 or 235 tyres.
- Change engine and gearbox mounts
- Maybe window tint, not sure yet
- Maybe a HID kit

[JaPPster]

svaka čast, majke mi!!

[igralec]

I dediced not to wait for spring (avoid sourcing a set off here and arranging transport from the UK) and got 17" wheels from a mate :)
http://img231.imageshack.us/img231/4905/17keom8.jpg
They're Enzo/AEZ Cup 17x17J ET40, fitted with temporary 5 year old winter tyres 225/45/17 and they don't fit at the front :wack: Looks like because of the 280mm EBC discs as the wheels are off a mate with an S13 with 257mm front brakes and before fitted to another S13 with 280mm standard brakes :annoyed:
Hope getting spacers made will do the trick :)

[200sxslide]

looking good mate keep up the good work:D and let me know what 1/4 mile time u do as want basicly the same spec as u for my s13 for when i compete in the prostreet drag series next year thanxs mate:thumbs:

[igralec]

Tnx mate :thumbs:
Drag race season starts in late april next year i think, so it'll be a pretty long wait :D
This year i couldn't compete because:
1. race - engine was being rebuilt, waiting for parts and stuff
2. race - clutch was slipping
3. race - 1/8 mile, car wasn't taxed + clutch slipping
4. race - 1/8 mile, t28 died
5. race - event cancelled
6. race - never happened
:wack:

i'll try and get some gtech measurements as soon as i can, it's a shame i never bothered with 1/4 mile runs with it, only 0-60mph :annoyed:

it was 5.9s with full stage 1 and 5.3s with full stage 2... hoping for sub 5s now despite open diff and winter tyres :wack:

[igralec]

Received an HKS EVC III boost controller today, too bad it didn't come with a simple harness rather than 20 individual plugs, but i'll hopefully fit it and set it up during the holidays :)

http://i150.photobucket.com/albums/s81/igralec/project-thread/EVCIII.jpg

EDIT: got everything fitted and finished today, turned down the actuator boost. Due to the roads being very icy i'll have to wait a couple of days set up the controller and see if it works :D

http://i150.photobucket.com/albums/s81/igralec/project-thread/evc3_1.jpg

http://i150.photobucket.com/albums/s81/igralec/project-thread/evc3_2.jpg

[igralec]

time for an update after a couple of months :)

Not much done really, changed some vacuum pipe, set up the EVC, done an oil change (running Liqui molly race tech GT1 10W-60), fixed the afm to turbo pipe sucking shut at the bottom where it's still the rubber elbow.

Scheduled for dyno in 4 hours time, hoping to break 300hp @ 1.3 bar :D

[TM_S13]

nice !
tell us the news after that ;)

[M.D.]

good work, i have that boost controller and it works brilliantly and is really simple to use too, dunno if its any use to you, but i used to have mine mounted where yours is and i made a pannel to fill in the space around it, ill post it to you if you like

[igralec]

thx for the offer m.d., but i'll probably get some carbon fibre plates :)

well nothing to report, waste of time really. There's an old man with a furniture shop or something 10ft from the dyno and he started moaning when a mates s13 did a couple of runs. Since my car is even louder we had to call it a day.
I'll have to wait a couple of weeks when the dyno shop gets new sound isolation and a better cooling fan. Hope it will be worth it, maybe a few extra hp with fresh air :wack:

[igralec]

I've just had LSD fitted, after 3 years of driving with an open diff :wack: interesting how different the car feels when taking off slowly, not to mention the other stuff :p Now i just need some rain to get used to it :nod:

[JAKAN]

...and don"t crash at first rain. Awsome project nice work:sxoc:

[igralec]

Wish me luck, I'll be doing my first drag race event tomorrow :thumbs: it'll be interesting to see how bad winter tyres do but i'm hoping to be in the 13s (a sub 13.5 without reaction will be a good result as far as i'm concerned, will bring a helmet and racing gloves as they are required for sub 14 sec times) :wack:

done a tiny bit of weight reduction, removed the spare wheel and will remove the passenger seat tomorrow in the pits :)

[Pablo13]

Good luck igralec :thumbs:

[igralec]

It was a fairly good day, but it was fairly hot which showed on 0.1 bar less boost and i think the air filter was suffering from heat sink pretty bad (it's touching the hot pipe). The 195/55/15 winter tyres weren't as bad as you'd expect, but they cost me a podium finish, maybe even a win if i had a bit more experience with drag events :D

Don't have any official times yet, but i think they were:
1st qualifying run: 15.1, forgot to start and then bogged down as i wasn't really paying attention because i was racing a 997T :wack:

2nd qualifying run: 14.3, a good run but i was really suffering on starts, the car didn't go off the line when i wanted, so the RT was around 0.5s.

1st race in 14s class: was racing a girl in a 210hp civic VTI... turned boost from 1.25 to 1.3 bar :p got a pretty good start but missed 3rd :wack: managed to beat her anyway in the last couple of meters. I was told there was a pretty big terminal speed difference :p

2st race in 14s class: was racing a guy i know with a 250hp impreza. again a good start for winter tyres, thei mpreza murdered me on the start, but i almost got him back at the finish, but lost out by less than 0.1s :wack: He then said he was trying to make sure he's stay in front and try not to break into the 13s. If have gotten 0.2s on the start, i don't think he could have matched me above 80mph. The guy then finished 4th, lost out to a 2.9L MX3 with around 300hp while trying not wo go sub 14 again :D 2nd was a guy with a civic VTI, best time 14.4 i think, and the winner was an E46 M3 (was taking it easy and went full throttle in the last 100m of the finals :wack:

all in all it was pretty good for the first time, i think my best ET was 13.7 or 13.8, best terminal around 109mph ubt i'll chech the official results when they're online :thumbs:

event of the day was an old man in a corvette C6, the spun on the start, then got it facing the right way and spun again into the cones :confused::wack:

http://s150.photobucket.com/albums/s81/igralec/drag%20race%20SG/
first pics i found added into the album :)

[igralec]

Well after almost 3 months of not doing anything to the car, i guess there's a reason for that.

I've recently come to the conclusion that i want a newer car and that there's no use spending more money on this one, as it won't be worth any more than before. Also after 3,5 years of ups and downs, i've gotten tired of it and need a change (something with AC, a stereo and not stupidly loud :wack: ). Looking back at all the work done to it, it in my eyes doesn't really justify all the money spent anymore.

If and when i manage to sell it for a nearly decent amount, i'll get something 12-13 years younger, AWD, hopefully blue with gold wheels and a big rear wing :p

Until then the s13 will remain my daily driver and i hope it doesn't break down in the near future :wack:

I'd like to thank all the people here for posting interesting threads full of info (i'd probably be running a diesel turbo at 32psi if it weren't for the SXOC) :wave:, helping out, being ready to post items abroad to me and so on :thumbs:

Cheers,
:sxoc:

P.S. i'm not leaving, i'll just try and avoid the traders section and for sale threads :wack: might have to cut down on reading the project threads too :p