PPS - S15.3 - Supercharged RB30 - Driftcar Project

[Jeffers_S13]

As if we haven’t got enough to do in between our day jobs and running PPS, we decided to go ahead and build a drift car…:wave:

Car / Shell / Chassis - We have discussed the idea many times before even starting the breaker business. As is the usual ‘want’, we wanted to be just like everyone else…and be different. So, looks wise, inspiration came from the S15.3 MASA car.

http://i43.photobucket.com/albums/e356/Jeffers_S13/180-s15.jpg

We hadn’t seen many around at that time (still haven’t seen another one ?) and we both think it looks ace, ours will look somewhat different though as we are using a combination of parts and panels to get ‘our’ look.

Engine - Power plant wise, again, we wanted to be like everyone else and do something different, so a supercharged RB30 it is with lashings of extra power, so we sold the engine and turbo it came with. Why a supercharger ? I can hear people saying. The answer is a simple : ‘because’. We are aware that there are turbos that will spool up so quick they seem like a supercharger and how superchargers ‘sap’ power etc etc etc and without wanting to get into a massive debate (please refrain from questioning it in this thread :whip: ) the answer is simply ‘BECAUSE’ it’s a little different and it will sound really cool :)

Driving - Although Dave and I like to have a go at driving cool stuff and have driven a few cars in our time we simply aren’t good enough to compete and do well so I asked a mate of mine, Scott Armstrong, if he’d be keen. You don’t wanna know what he offered for the chance, but needless to say, he was pretty keen…Scott is a professional driver and works for Continental Tyres based at MIRA. He gets to drive all sorts of cars, on all sorts of tyres, on all sorts of surfaces all over the world, at their limit and be able to give objective opinion...and he gets paid for it, some peoples dream job :wack: so, he ought to have the qualities needed to be competitive, after a few rides with him on various occasions Dave and I, in our humble opinions, are confident in his abilities...:smash: Scott has had a few attempts at the 'drifting' thing but lack of reliable car (yes, he owned the orange V8 Sierra for a while and still owns the Datsun rally car) has always hindered him, here's hoping we can change this. edit : He also won the autocar sideways challenge in a Capri about ~100 years ago.

So, on with the search for a 15. A bit of effort later and Dave found one in Japan through an agent with light front end damage and a few goodies already bolted on.

http://i43.photobucket.com/albums/e356/Jeffers_S13/S15Damaged29.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/S15Damaged41.jpg

SARD blade roll-bars

http://i43.photobucket.com/albums/e356/Jeffers_S13/S15Damaged17.jpg

Zeal coilovers and adjustable arms

http://i43.photobucket.com/albums/e356/Jeffers_S13/S15Damaged26.jpg

Several weeks passed and finally it arrived at Liverpool docks so we took a day off work and nipped up to fetch it.

http://i43.photobucket.com/albums/e356/Jeffers_S13/DSC00008-1.jpg

All sorts of other cool stuff in the car park...oh and there were some Impreza's aswell...

http://i43.photobucket.com/albums/e356/Jeffers_S13/DSC00009-1.jpg

Back at my place we got to work stripping the interior. EVERYTHING went and the shell was totally stripped bare, nasty job of removing the sound deadening fortunatley avoided by me whilst nursing a hangover...

http://i43.photobucket.com/albums/e356/Jeffers_S13/Passenger_footwell2.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/IMG044.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Passenger_footwell.jpg

Note that the sill cavities seem to be filled with stiffening foam, an indication that the car has had competitive past perhaps ???

[Jeffers_S13]

Leftovers :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Removed_Deadening2.jpg

Front end before spanner twirling...

http://i43.photobucket.com/albums/e356/Jeffers_S13/Front_End3.jpg

and front end now...errr...modified.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Front_end2.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Front_end.jpg

Thats the donor engine you can see in one of the pics, we will only use the block and crank, and also a brief appearance by Scott :smash:

[jontruman]

sounds like its going to be a good thread, keep the pics coming

[Jeffers_S13]

Basic details of engine are RB26 head mated to the RB30 block, RB30 crank with custom pistons and rods.

RB26 donor :
http://i43.photobucket.com/albums/e356/Jeffers_S13/DSC00006.jpg

RB30 donor, in need of some TLC :
http://i43.photobucket.com/albums/e356/Jeffers_S13/RB30_Block.jpg

Note height difference between blocks, 26 on left and 30 on right.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Front_RB26_Shrunk.jpghttp://i43.photobucket.com/albums/e356/Jeffers_S13/Front_RB30_Shrunk.jpg

[ex-ctr]

where do you guys find the time:eek: should be a monster:nod::D

[Jeffers_S13]

where do you guys find the time:eek: should be a monster:nod::D

We try and do 25hr days whenever possible :wack:

[ex-ctr]

We try and do 25hr days whenever possible :wack:

you building it over the farm, what engine management will you be using and what supercharger i was looking at one from the usa that was very compact almost turbo like but i have forgotten the site/link:(

[B_rice]

It's an amazing project you build an s15 with facelift s13 ? I don't understand :lol: What the next stage ?

[David Reid]

It will use emerald (very similar to Vems) with a Paxton SC, will add pics when it arrives, its just as you describe.

[David Reid]

an s15 with facelift s13 ? I don't understand :lol: What the next stage ?

Because its :cool: and every one in EDC has S15 fronts

Its having its cage and tubs fitted at the moment. Then we will have a major push to get the shell painted inside and out in the 1st week of Jan.

[800bhp]

looks exciting :)

[Jeff]

Good work fellas :thumbs:

[TheChin]

May i be the first to say. I hate you :thumbs::(

[FIGJAM]

The farm is going to be a busy place over the next few months....fantastic work

[The_BULK]

cool work guys, will be good to see something different :D

[scimmy ben]

It will use emerald (very similar to Vems)

Have you bought it yet? Not enough coil drivers for my liking :no: you're going to run wasted spark I assume.

ETA - That sounds hyper critical... its not meant to. The car looks like its going to be be very cool.

Did the bonnet survive the impact?

[pyro]

That's balls out. Cool. :D
...er...what're you doing with the 15 drivetrain?

[Jeffers_S13]

Yes, wasted spark. We are using crank based signal not cam based also for much better accuracy. Builders on GTR forum using cam based have had wonder issues at around ~7,250rpm.

Bonnet is in one piece but is a bit mullered, will need repairing, we cant use it as it doesnt suit the 13 front end. Its in a storeroom at my place :)


Have you bought it yet? Not enough coil drivers for my liking :no: you're going to run wasted spark I assume.

ETA - That sounds hyper critical... its not meant to. The car looks like its going to be be very cool.

Did the bonnet survive the impact?

[Jeffers_S13]

That's balls out. Cool. :D
...er...what're you doing with the 15 drivetrain?

We have sold the engine so far, if you're interested in anything please PM me or David or see thread in our section, we cant talk shop here.

[30psi]

Good luck sounds like fun :thumbs:

I'm really surprised at the difference between block heights though.

[Jeffers_S13]

I'm really surprised at the difference between block heights though.

Yeah, the angle that pic is taken from seems to make it seem like a really big difference, it doesnt seem that big in reality, Ive got some pics from the side aswell somewhere but I cant find them :rolleyes:

[stueywalls1]

I love the look of it with the 13 front end.

Can I ask what company you used to get the car into liverpool docks please.

[Jeffers_S13]

Can I ask what company you used to get the car into liverpool docks please.

Various companies involved in actually getting the car onto UK soil (so to speak).

Power Vehicles
Total Service Yamaguchi Co. Ltd
Yuw Autotrade Logistics Ltd
Liverpool Freeport (Mersey Docks and Harbour Co)

[30psi]

Yeah, the angle that pic is taken from seems to make it seem like a really big difference, it doesnt seem that big in reality, Ive got some pics from the side aswell somewhere but I cant find them :rolleyes:

Yeah the position of the water pump may make the difference more misleading.

Was the RB30 single cam only? Reason I ask is that I assume the extra deck height may have issues on a standard RB26 cambelt. Not in terms of timing as I'm sure you'll be on verniers but purely on length. Hopefully its a minor effect and the tensioner has the flexibility to take it.

[Jeffers_S13]

Yeah the position of the water pump may make the difference more misleading.

The water pump is in the same place, the blocks are very similar, its interesting comparing the two side by side.


Was the RB30 single cam only? Reason I ask is that I assume the extra deck height may have issues on a standard RB26 cambelt. Not in terms of timing as I'm sure you'll be on verniers but purely on length. Hopefully its a minor effect and the tensioner has the flexibility to take it.

Yes, single cam, cambelt needed for this is from a Diesel Mazda 323 something or other, Ive got the detail somewhere...

[Parker]

Awesome project :clap:

[Pablo13]

Great choice of car, Ive always liked the masa car in videos exactly because it was different.

Great choice of engine too! Ive been in the early stages of pondering this RB conversion myself as my sis is in aus at the moment. Did you get the block from Austrailia (commadore) as Ive heard its hidden in some patrols too?

[Pete C]

Ive heard its hidden in some patrols too?

Like this one maybe?

http://cgi.ebay.co.uk/Nissan-Patrol-SWB-2-litf-33-all-terain-tyres_W0QQitemZ140189704788QQihZ004QQcategoryZ1823 8QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

[Pablo13]

Like this one maybe?


Could well be, I am not too up on the exact model of patrol needed.

[Jeffers_S13]

I was in the garage briefly last night so I took a few pics of some of the bits we have to go on :

Calipers :

http://i43.photobucket.com/albums/e356/Jeffers_S13/19122007179.jpg

Handbrake :

http://i43.photobucket.com/albums/e356/Jeffers_S13/19122007173.jpg

Roots type charger off an XKR, its been patiently waiting and collecting dust in my garage for months ! we are most likely NOT using this now though as we are NOW FITTING AN EVEN BIGGER ONE !!! :smash:

http://i43.photobucket.com/albums/e356/Jeffers_S13/19122007172.jpg

And the nicest piece of kit, an OS Giken triple plate clutch.

http://i43.photobucket.com/albums/e356/Jeffers_S13/19122007174.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/19122007178.jpg

[Paul_S13]

Its the M90 from the straight 6 Jag that has a shorter nose and will fit in, I almost had it there on a CA but it's on hold coz im skint :(

[FIGJAM]

Do all the M90 chargers have the same nose, if so you can pick the up on the cheap from the US, about £100 if I rememeber right (dont ask why I was looking). They are used on a lot of GM cars

[McRearout]

Great project - S13 nose on an S15 looks soooo good :nod:

[Randers]

Sounds like this will be a beast, power and good looks...:clap:

[Jeffers_S13]

Car arrives at the welders.

http://i43.photobucket.com/albums/e356/Jeffers_S13/PICT0093_small.jpg

Surrounded by grass specials and various other projects he has on.

http://i43.photobucket.com/albums/e356/Jeffers_S13/PICT0095_small.jpg

Trial fit of some of the panels (sorry for poor phone pic) GRP Wide rear overfenders (not really visible) and EP Racing front GRP wings, and the :cool: 'raceonusa' headlight shells.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Light.jpg

[Ady682]

looks like its gonna be an awesome project, just a quick question though are the wings your using s13 or s15 and how have you had to modify them? looking at doing something similar to my s14, and just wondering if its the front end you modified to fit or if its two wings spliced together, the front from an s13 welded to the rear half of an s15 wing. any help greatly appreciated

[tokyo_black]

This is going to be a really special S15 :)

I *love* the initial picture, i've had that knocking around my pc for years as an example of the 'perfect s15'.

[Jeffers_S13]

Through fear that this project may now be thought of as yet another pipedream/also-ran and that most people may be just awaiting the final and standard reply in the style of either :

'ran out of time'
'ran out of money'
'plans have changed'
'moving house' etc etc

and the inevitable ebay advert that then follows...

...here is some progress ! :sxoc:

I didnt want to add a progress reply until we had the shell painted but as usual its taking waaaay longer than we hoped to get stuff done, plus we've done a few extra things we didnt plan for which is adding time. So this is just a quick update and I will do a proper more detailed one after we have painted it. This should now, hopefully, happen next weekend.

Just after Christmas we made the journey to Wales to get the car back from Endaf also dropping the green 14a at Fishguard to be collected. He had not quite got everything done unfortunately due to all the cars he'd been doing for Autosport, but we were desperate to get stuck in so we took it as it was.

The main cage was in, as were the front tubs :cool: cage is fairly standard, door bars and cross behind main hoop linking to tops of rear turrets. We have also tied the front turrets in with some diagonals that extend upwards and through the front bulkhead. Webbing was added for additional support and bling :)

http://i43.photobucket.com/albums/e356/Jeffers_S13/05012008204small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/05012008203small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/05012008208small.jpg

Before and After
http://i43.photobucket.com/albums/e356/Jeffers_S13/PICT0097small.jpghttp://i43.photobucket.com/albums/e356/Jeffers_S13/05012008200small.jpg

We loaded up and headed home. We decided to do all initial mucky work like welding and grinding at the unit so my Rush didnt get sprayed with sparks or recieve any dents etc so we emptied the unit of scrap cars and made it into a make-shift workshop as we only expected to be there a week or so...LOL ! normal business service shall resume shortly :smash:

We both took a few days off work and got stuck in with some very looong days and nights at the unit. Both seats now have mount positions, here is drivers seat in position after lots effort and trial fits with Scott (with helmet on) sitting in it, also the steering column now has supports welded to the cross bar and the boss has arrived although we need to get a round wheel for Scotts preference. Driver seat is adjustable as is the angle of the steering wheel so me and Dave can drive the car on practice days, the passenger is notionally fixed but can be moved.

http://i43.photobucket.com/albums/e356/Jeffers_S13/22012008319small.jpg

Dave spent a couple of days tubbing the rear arches (no pics!) and trial fitting and trimming the overfenders and a wheel.

Rear
http://i43.photobucket.com/albums/e356/Jeffers_S13/11012008240small.jpg

Front
http://i43.photobucket.com/albums/e356/Jeffers_S13/20012008301small.jpg

The engine and gearbox have been in and out a few times now, here it is a little dressed up for the pic.

http://i43.photobucket.com/albums/e356/Jeffers_S13/13012008257small.jpg

And thats all for now, needless to say we have been working our asses off on it, every night till 11pm and all weekends, which means a lot of grief off the gf's, but it will all be worth it :) Scott comes down as much as possible when he isnt not away with work on some driving jolly in Spain or Germany !

LOADS more stuff has been done but I'll do a more detailed write-up after its painted and it looks a bit better :)

[Kieran_E1]

purely out of interest and with absolutely no disrespect to scott as he's a good bloke, but given the announcement about edc licenses the other day if all existing drivers take up their slot he won't be able to compete in edc without first competing and winning a BDC event. do you have a back up driver planned?

[Madda]

Awesome project guys. Its looking great :cool:

[Jeffers_S13]

No back-up driver. Yes, thats a bit annoying but due to Scott's lack of a useable car last year and that the organisers believe he hasnt shown his full potential we have been told that we can enter the BDC and then hopefully get promoted to the EDC, assuming the car is up to scratch and is driven well.

[Jeffers_S13]

Awesome project guys. Its looking great :cool:

Thanks :)

Any comments and questions on other stuff and in general appreciated maybe someone will point something out we havent considered ? :wave::smash:

[Kieran_E1]

No back-up driver. Yes, thats a bit annoying but due to Scott's lack of a useable car last year and that the organisers believe he hasnt shown his full potential we have been told that we can enter the BDC and then hopefully get promoted to the EDC, assuming the car is up to scratch and is driven well.
yeah his stanza , while cool wasn't the best and the sierra was not too hot either.

hopefully he'll get back up quickly

[Jeffers_S13]

yeah his stanza , while cool wasn't the best and the sierra was not too hot either.

hopefully he'll get back up quickly

Yes, thats having a total overhaul at the mo ! so he is torn between helping us and doing that and the less said about the Sierra the better :wack: ! ...it did sound really :cool: though.

[ex-ctr]

seen this in the flesh and its going to be a monster:nod: also do you want to borrow my 1mtr folder for a couple of weeks

[Jeffers_S13]

Thanks, it might be useful, I'll give you a bell when we could do with it :) all the bigger stuff is folded, theres only the bit in the area behind the passenger that needs panelling and still not decided how that will be, thanks for the kind offer :sxoc:

[David Reid]

yeah his stanza , while cool wasn't the best and the sierra was not too hot either.

hopefully he'll get back up quickly

If his driving in a completely standard S Type (open diff)is anything to go by i.e through into roundabout at 60 mph and hold on on the limit of the lock I am confident he will do well. He is driving sideways everyday so we have every confidence in his abilities.

Scott is in discussions with the organisers and it is a pity it looks currently like we wont be able to straight into the 1st round of EDC. Especially as he does hold a current D1 license.

But we'll have to wait and see what happens, this car is going to be exactly the type of car the organisers are looking to have in EDC.

No pictures of my beautiful strut brace :cry:

[Seccy]

This is going to look tough as...

The cage looks like a work of art on its own.

[Kieran_E1]

If his driving in a completely standard S Type (open diff)is anything to go by i.e through into roundabout at 60 mph and hold on on the limit of the lock I am confident he will do well. He is driving sideways everyday so we have every confidence in his abilities.

Scott is in discussions with the organisers and it is a pity it looks currently like we wont be able to straight into the 1st round of EDC. Especially as he does hold a current D1 license.

But we'll have to wait and see what happens, this car is going to be exactly the type of car the organisers are looking to have in EDC.

No pictures of my beautiful strut brace :cry:

don't get me wrong , i know he can drive and wasn't knocking that side of things, just as he was let down with a vehicle etc he didn't compete last year and has to go through the pain barrier of re-qualifying which is a royal pita

[Jeffers_S13]

No pictures of my beautiful strut brace :cry:

:rolleyes: ...and the only half decent pic I have of Dave's strut brace...

http://i43.photobucket.com/albums/e356/Jeffers_S13/14012008282small.jpg

[David Reid]

don't get me wrong , i know he can drive and wasn't knocking that side of things, just as he was let down with a vehicle etc he didn't compete last year and has to go through the pain barrier of re-qualifying which is a royal pita

No offence taken, EDC admin have not confirmed that to Scot, but yes that is what we fear will have to happen.

Lets keep the thread about the car now, pm if you want to discuss further

[David Reid]

:rolleyes: ...and the only half decent pic I have of Dave's strut brace...

:D

[Kieran_E1]

No offence taken, EDC admin have not confirmed that to Scot, but yes that is what we fear will have to happen.

Lets keep the thread about the car now, pm if you want to discuss further
apologies for the hijack, lovely car and excellent workmanship:thumbs:

[Quail]

How did I miss this!?!? This is going to be awesome! Can't wait to see this come together :D

[Jeffers_S13]

As Ive got a a fairly good collection of pics for this little bit of the car I thought Id add a few pics to show the process.

First remove floor section required, I used a jigsaw and an angle grinder :

http://i43.photobucket.com/albums/e356/Jeffers_S13/14012008285_small.jpg

Then I tacked a piece of box section in to give support for the new floor

http://i43.photobucket.com/albums/e356/Jeffers_S13/20012008296small.jpg

Then I spent several hours making a cardboard template of the new floor. Basically its lots of fitting and trimming until your happy with the fit. Time spent here saves a lot of faff later on. I didnt get any pics of the template Im afraid, it got soaked in water after a small spill...

Then you transfer the shape to a suitable sheet of steel and cut it out. Also no pics of the fresh cut piece ! then after lots of headscratching and measuring, the shape of the floor was decided and I cut and bent the centre of the new sheet, heres a pic of the shaping in progress (still not welded in).

http://i43.photobucket.com/albums/e356/Jeffers_S13/20012008299small.jpg

Then I measured up for the front and back side panels and made cardboard templates of the important end bits.

http://i43.photobucket.com/albums/e356/Jeffers_S13/20012008307small.jpg

...and the new floor was a bit easier so I just cut one after a few quick measurements

http://i43.photobucket.com/albums/e356/Jeffers_S13/20012008305small.jpg

Then I swaged the front and rear panels and the floor for added stiffness

http://i43.photobucket.com/albums/e356/Jeffers_S13/22012008316small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/22012008318small.jpg

Then it was all tacked in for trial fit before final bashing and welding

http://i43.photobucket.com/albums/e356/Jeffers_S13/28012008351small.jpg

This was done over a couple of weeks, fitting in around other jobs, a lot more effort needed than the pics suggest :smash:

[Evilchap]

Perhaps a silly question, but why steel and now aluminium or composit for the boot floor?

Ben

[Jeffers_S13]

Dave wanted to do a side exit exhaust...would only take an evening he said...:wack::D

Not many pics of this unfortunately, but it was a lot of effort to get it to fit, lots of cutting and jiggling and bashing.

First of all you need to cut up a perfectly good Apexi exhaust :cry:

http://i43.photobucket.com/albums/e356/Jeffers_S13/14012008289small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/14012008288small.jpg

Then you decide where the exhaust is going to stick out and realise its gonna be a very tight fit through the inner wing and arch. So it comes out where it will actually fit.

Then you cut holes through the perfectly good rear quarter and equally good rear quarter overfender :smash: and poke it through.

http://i43.photobucket.com/albums/e356/Jeffers_S13/15012008291small.jpg

Then you spend hours cutting and tweaking to get just the right curve and then buy a 90deg bend to get it facing the right direction. Then make a frame around the exhaust so it can be boxed in and lagged to meet regs and also design a mounting system to enable removal in the future, et voila :

http://i43.photobucket.com/albums/e356/Jeffers_S13/28012008360small.jpg

This part is rigidly mounted to the car, there will be a large flexi section between it and the downpipe.

And the exhaust tip cut almost flush with the overfender :

http://i43.photobucket.com/albums/e356/Jeffers_S13/04022008392.jpg

[Jeffers_S13]

Perhaps a silly question, but why steel and now aluminium or composit for the boot floor?

Ben

We have the tools to weld steel, we dont have tools to weld ali and its far easier to work with and more familiar to both of us than GRP and the like.

[30psi]

How did you swage those panels?

[Actual_Ben_Taylor]

Hmm, really not digging the side exit :(

[Jeffers_S13]

How did you swage those panels?

With a swaging machine of course ! :p :)

One of our recent toy purchases :cool: will be useful for many projects in years to come no doubt.

[30psi]

Hmm, really not digging the side exit :(

Not me either, it could do with being cut so its in line with the body panel

[Jeffers_S13]

Hmm, really not digging the side exit :(

Have faith ! I trimmed it 10mm flush with the overfender yesterday (have no pic though) looks far batter than these pics suggest...when its boxed in will look OK.

Or do you not like it for another reason ?

[Jeffers_S13]

Not me either, it could do with being cut so its in line with the body panel

See above, already done, I will take some pics tonight and you will be relieved, these pics were 'work in progress' at the time we were doing it...

[Evilchap]

Is it done for reasons of asthetics or shortening the exhaust run?

[David Reid]

Is it done for reasons of asthetics or shortening the exhaust run?

Asthetics and stopping it from grounding out. Its a GT spec I cut up :wack:

[Actual_Ben_Taylor]

Have faith ! I trimmed it 10mm flush with the overfender yesterday (have no pic though) looks far batter than these pics suggest...when its boxed in will look OK.

Or do you not like it for another reason ?

Just not keen on the overall look tbh.

[Jeffers_S13]

Is it done for reasons of asthetics or shortening the exhaust run?

Both really, lack of exhaust trailing underneath means less to repair following off's. But probably more to generate interest and for showmanship, flames being spat out from the side will make for some good photos. The purpose of the car is to generate interest so it gets noticed for the good of PPS.

[Jeffers_S13]

Just not keen on the overall look tbh.

OK, I agree the pics dont show it in its best light. The finished article wont look quite so daft, now its cut flush it looks good IMO :)

I have some pics of the outside of the car from our work this weekend but not a set to make a story up from, so they will have to wait.

[Jeffers_S13]

A little update, last week Scott stripped all the suspension and removed all the bushes. We then had all the arms shot blasted and powder coated. I dont have any pictures of them before or blasted, but heres some of the bits finished.

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D28F3180D48911DCA87F3E04521FD22D.jpg

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D401AD40D48911DC9E948C62521FD22D.jpg

Rear Arm

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D4F31220D48911DC9866A5D3521FD22D.jpg

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D5705870D48911DCB25C1FC5521FD22D.jpg

Notice the extra strengthening on the S15 Type R bottom wishbone

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D5D8B730D48911DC880CF124521FD22D.jpg

Stock s14 for comparison

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D653B390D48911DCA059B486521FD22D.jpg
http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/D6B92C20D48911DCB7D63531521FD22D.jpg

Cusco upper arm

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/98B0C810D48A11DCAC1AD14E521FD22D.jpg

The rest will stay wrapped until we have painted the shell and start the reassembly

[McRearout]

Liking the exhaust :nod:

[FIGJAM]

Just to give you a feel for the RB30 superchaged noise, you can really hear it in the last 30seconds

<object width="425" height="355"><param name="movie" value="http://www.youtube.com/v/s4f-ch-olOo&rel=1"></param><param name="wmode" value="transparent"></param><embed src="http://www.youtube.com/v/s4f-ch-olOo&rel=1" type="application/x-shockwave-flash" wmode="transparent" width="425" height="355"></embed></object>

[Smoothound]

That MASA car looks the dogs! I'm loving this S15/S13 combo!

I'll be watchin closely! Good luck! :thumbs:

[Quail]

Just to give you a feel for the RB30 superchaged noise, you can really hear it in the last 30seconds

That sounds awesome :notworthy

Did the police turn up at the end or something?! LOL

[Jeffers_S13]

Just to give you a feel for the RB30 superchaged noise, you can really hear it in the last 30seconds

<object width="425" height="355"><param name="movie" value="http://www.youtube.com/v/s4f-ch-olOo&rel=1"></param><param name="wmode" value="transparent"></param><embed src="http://www.youtube.com/v/s4f-ch-olOo&rel=1" type="application/x-shockwave-flash" wmode="transparent" width="425" height="355"></embed></object>


Goddammit, I cant view this at work :(

[FIGJAM]

Thats a bugger, all I can say is if yours sounds 1/2 like that you will be very very happy:)

[Jeffers_S13]

At home so I see it now :) Is that a Commodore ? if its got the kit fitted Ive seen on various sites then that blower is :ghey: compared the Behmoth we are fitting ! also they dont seem to run any sort of IC or chargecooler ? We are using a positive displacement twin screw blower at about 17,000 rpm and through a massive oversized GTR style FMIC. We're really hoping it will have a loud and distinctive whine...it will certainly look the part in the engine bay :)

[FIGJAM]

[QUOTE=Jeffers_S13;3802338]twin screw blower at about 17,000 rpm QUOTE]

Yep, that should stand out a mile:thumbs:

[kingj]

This project is f**cking cool.
The side exit exhaust is f**cking cool.
end of.:D

[blue boy]

Very nice project lads.

I like the exhaust:thumbs:

[Nis]

You dont always have to have an intercooler.....

http://i257.photobucket.com/albums/hh217/thedarkwarrior_300zx/1.jpg

Ivan

[andyfield]

Awesome project, can't wait to see it finished!

[Jeffers_S13]

Over the last week we have been fitting the front end. Basically most of it doesn't fit and needs modifying.

We decided we needed a starting point to work from, so I made some S13 bonnet hinges to fit the s15.

First a bit of cutting.

http://i43.photobucket.com/albums/e356/Jeffers_S13/27012008335small.jpg

Then I shortened them by about ~20mm and re-welded, in effect moving the bonnet 20mm forwards, sorry for poor pic.

http://i43.photobucket.com/albums/e356/Jeffers_S13/28012008362small.jpg

Dave worked on the bodykit and found the S13 wings didnt fit the S15 door very well as you might expect.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02022008380small.jpg

So next he cut the back of the wing to line up with the door

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/147A8210D8DC11DC8DC0B087521FD22D.jpg

It still stuck out too much at the bottom so the bottom lip was cut off and moved over by 15mm.

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/12B21E20D8DC11DC99E74276521FD22D.jpg

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/167D2FE0D8DC11DCBCCD652B521FD22D.jpg

The top edge then didn't line up with the door, it was recessed, so Dave made up a support each side to push the wing out enough to match the profile of the door.

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/1AAD1DF0D8DC11DC944B16D0521FD22D.jpg

While we were messing with them Scott filled the swage lines that dont fit with the S15 lines.

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/13B3FDC0D8DC11DC8C6ABF14521FD22D.jpg

Refitted its starting to look better

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/1B8C5A60D8DC11DC8D5129DE521FD22D.jpg

Next the body kit arrived, we lined the front edge of the bumper to the bonnet and drilled some holes to fit it. Ive made some fabricated brackets that support the bumper and intercooler, but they aren't quite finished so we'll save them for the next update.

The rear bumper is a standard S15 one and it was really nice to find that with a bit of hole filing it went on easily.

I then fetched the bonnet from EP Racing, but due to the height of the RB30, the pulley fouled on its underside so it had to have a small hole cut:-

Before

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/1C73AD20D8DC11DC8AF12B56521FD22D.jpg

After

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/BBEB3170D8DC11DCB955B9F1521FD22D.jpg


Im not keen on the engine sticking through the bonnet. The alternative discussed is to extend the 1st fin until it reaches the back of the second fin covering the cam cover. Opinions /suggestions welcome.

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/B0518710D8DC11DCBCE9814F521FD22D.jpg

Finally we laid the skirts on which still need some work to get them to fit around the doors and need 10mm taken out of the front edge. But you can start to get an idea of what it going to look like.

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/B85B05D0D8DC11DCAAF3784C521FD22D.jpg

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/B96D3920D8DC11DCA855CB6A521FD22D.jpg

http://www.magix-photos.com/mediapool21/C9/BF/81/E0/42/8B/11/DB/86/18/48/96/52/13/B9/E6/oma/10/A97E5180D8F411DC8E547DEA521FD22D.jpg

The end of the fabrication/modifying is also in sight and I for one cant wait to get on with painting and putting it back together.

[Brian Griffin]

A lot of work there - its really taking shape - and i dont think you will really notice the bonnet modification to allow for the engine when its all painted. What colour is it going to be?

[Petrol]

Just read this and what can I say other than a fantastic project :notworthy For me it has everything :thumbs: Best chassis and best looking front end ;) I take my hat off to you guys for deciding to you use a professional driver :notworthy You can mod a car as much as you want but a proper driver makes a mahoosive difference :nod:

Keep up the good work and keep them pics coming :)

[Rich_M]

This is an awesome project, i really look forward to every update. Top quality work!:thumbs:
Rich

[Pete C]

Disappointed that it isn't going to have pop-ups. I know it's a lot of extra work, but...

Apart from that, I take my hats off to you fellows :notworthy

[Ryanmt]

http://aycu30.webshots.com/image/29469/2002997193581828150_rs.jpg
http://aycu18.webshots.com/image/29977/2002908032459080477_rs.jpg

more pics of the first car posted. I hope yours looks this cool :D

[kingj]

This is coming along nicely:nod: good luck with it guys,any idea what colour to paint it yet?

[gander]

looking really nice. im a big fan of the exhaust.

[Ol'_200sx_thing]

I soooo want one of those :notworthy

Fooking lovely :D:nod:

[DanS14a]

I think it will look better then the one in the picture, cos the kit you are fitting looks a lot nicer. Keep up the good work

[Jeffers_S13]

With all the fabrication work now 99.9% complete (just the headlight supports to complete) we decided it was time to crank up the compressor and break out the paint. So whilst Dave and Scott got stuck into preparing the shell and suiting up for the arty bit (Dave will post details soon) I took the oily bits out the car and back to my workshop.

The straight six block is a massive lump and rather than put my back out attempting to lift I used the engine crane and trolley to get inside.

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008472small.jpg

There wasn’t a lot to do really to get it bare and ready for machining. First of all, main bolts out and girdle off.

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008476small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008478small.jpg

Then pistons out

http://i43.photobucket.com/albums/e356/Jeffers_S13/RB30_Rod_Piston2small.jpg

Then old oil pump and rear crank seal off

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008484small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008486small.jpg

Then crank out

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008488small.jpg

Oil pressure sensor off and engine mounts off, job done, ready for Chesman.

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008491small.jpg

Time for a tea

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008490small.jpg

Next the head…

[Jeffers_S13]

The head was more or less complete. I downloaded the RB manual from a link on skylineowners.co.uk, whilst that was chundering away I cleaned the bench and got the head resting on some wood blocks so open valves weren’t damaged.

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008495small.jpg

Then I removed the pulley cover, pulleys and back plate and un-did the cam caps in sequence on the exhaust cam, as usual its just concentric circles towards the centre of the cam ~1/4 turn at a time. Cam removed and put to the side exposed the lifters.

http://i43.photobucket.com/albums/e356/Jeffers_S13/01032008503small.jpg

Before pulling the valves out you need to pull each lifter out using a magnet and recover the shim, a quick wipe and put to the side (shim + lifter kept together).

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008510small.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008513small.jpg

Once all the lifters are safely out the way, the valves can be got to. To remove you need a spring compressor. Mine doesn’t quite have enough travel on it so I have to add a socket to get the spring to compress enough.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008505small.jpg

When it’s compressed you simply reach in the top and jangle the collets off the valve stem.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008506small.jpg

And recover with the magnet.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008508small.jpg

The spring and retainer can then also be recovered after this. Note orientation of the spring, close coils to the head, paint mark also shows which end goes to the bottom, just like on a CA18DET.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008518small.jpg

Lay all the valve gear out methodically, I tend to always work left to right, left being pot 1. It helps keep things tidy and together and also you can see at a glance if something is missing.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008515small.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008516small.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008517small.jpg

After a while removing the valves gets a bit boring, especially when there is 24 of them so I like to try and drop one of the tiny collets on the garage floor and then spend 1 to 2 hours crawling around on my hands and knees looking for it. It makes things all the more interesting if you have tonnes of junk stored under the bench where it may have dropped, but who knows, maybe as you dropped it, you accidentally kicked it across the other side of the workshop ?! it really is great fun and only adds a couple of hours to the job. I try and drop at least one during the strip down and sometimes if I’m feeling inclined during the re-build aswell :wack:

After a few hours everything is out and the head now waits to be taken to Chesman with the block.

http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008522small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/02032008525small.jpg

[Squares]

Looking good mate, removing all those valves must be a marathon!:smash:

[Quail]

This is going to be awesome. Its really coming together now.

[Tricky-Ricky]

Just had a read through this, and i have to say what a top job, nice to see things done properly, should be an awsome drift car when its finished plus a real looker:thumbs:

[Starks]

Projects looking awesome bud, keep it up :thumbs:



Also lovin the side exit, facing pavement side of course.... crispy pedestrians anyone? :smash:


(yes i know its only being drifted :wack:) Keep it up and good luck!!!

[gander]

dont suppose you have any more pics of your exhaust? inside the car and underneath?

did you mount the box deeper in the car or cut the tailpipe down?

[base-1]

After a while removing the valves gets a bit boring, especially when there is 24 of them so I like to try and drop one of the tiny collets on the garage floor and then spend 1 to 2 hours crawling around on my hands and knees looking for it. It makes things all the more interesting if you have tonnes of junk stored under the bench where it may have dropped, but who knows, maybe as you dropped it, you accidentally kicked it across the other side of the workshop ?! it really is great fun and only adds a couple of hours to the job. I try and drop at least one during the strip down and sometimes if I’m feeling inclined during the re-build aswell :wack:

Not a bad idea :wack: I fall asleep doing 8v heads....

[Evilchap]

What oil and water pumps you going with? Looking good btw :) Very impressive!

[Jeffers_S13]

Standard new water pump and a new N1 oil pump, we have a JUN drive collar to go on the crank.

[Jeffers_S13]

dont suppose you have any more pics of your exhaust? inside the car and underneath?

did you mount the box deeper in the car or cut the tailpipe down?

Dont seem to have many of the exhaust and the shell is bare again at the mo, as Dave is midway through painting it.

The back box part comes almost up to the outer skin, then through a shallow sectioned/mitred bend, then through a mandrel 90deg bend and joins up with a cut-n-shut front section before it gets to the CAT recess. The front will also be modified to suit our manifold and downpipe which only currently exists in CAD format :thumbs:

[Jeffers_S13]

Looking good mate, removing all those valves must be a marathon!:smash:

Tis a bit boring, but only half as bad as a modern V12 with 4 per cylinder...

[Evilchap]

I was wondering if you were going the N1 route, I have got N1 pumps for my RB26, wondered if it's normal, obviously must be!

[Jeffers_S13]

We ordered and received our rad a couple of weeks ago. Except we received an R33 rad not an R32. After some faff we actually got an R32 rad, as it turned out the guy we bought it off had all his R33 and R32 rads labelled back to front ! I can only imagine what a PITA it will be for him to contact all his customers and try and resolve the issue…:wack:

So what’s the first thing you do when you get a rad ? you cut bits off it, in this case the small locating pegs on the bottom.

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008465small.jpg

Reason being that in the normal mounting rubbers the rad sits too close to the bottom pulley, bearing in mind we have to have an additional drive pulley to run the blower.

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008458small.jpg

Theres some room in front of the normal position anyway that is normally occupied by the AC condenser.

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008457small.jpg

Moving the rad forwards means the standard pegs foul on the front chassis brace brackets. So I decided not to drill more holes in them and opted for a different mounting method.

So I took the standard mount brackets…

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008460small.jpg

Then cut and folded them around to make this :

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008461small.jpg

Then welded them onto the front of the chassis legs

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008463small.jpg

So it mounts like this

http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008467small.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/23022008466small.jpg

Ive just got to make some ali brackets no to weld onto the side of the rad, and then some straps over the top from the IC support bars Ive made will hold it steady.

[gander]

Dont seem to have many of the exhaust and the shell is bare again at the mo, as Dave is midway through painting it.

The back box part comes almost up to the outer skin, then through a shallow sectioned/mitred bend, then through a mandrel 90deg bend and joins up with a cut-n-shut front section before it gets to the CAT recess. The front will also be modified to suit our manifold and downpipe which only currently exists in CAD format :thumbs:

nice one :thumbs:

[stevec]

Looking good mate, removing all those valves must be a marathon!

Tis a bit boring, but only half as bad as a modern V12 with 4 per cylinder...


bet it is fun lapping them back in:mad:

nice build it is exactly what I wanted to do to my S15 but didn't have the courage..

/Steve

[Jeffers_S13]

Just before our brief interlude (<a href="http://www.sxoc.com/vbb/showthread.php?t=345769">Temporary S13</a>) I stripped the head and block. I also bought myself a die grinder and a hooge selection of cutters, flap wheels and sanders etc

I set about the head with my new toy naively thinking 'how hard can it be ?'

I took out all the inlet squish areas and blended the bowl as best I could, on each one :

http://i43.photobucket.com/albums/e356/Jeffers_S13/10032008558.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/10032008559.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/10032008556.jpg

I also took the lumps out of all the exhaust ports, being very caeful here so as not to break into the water jacket :

http://i43.photobucket.com/albums/e356/Jeffers_S13/11032008569.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/11032008571.jpg

I also cleaned up the water jacket ports to match the gasket.

Then realising the mammoth task and ease in which I could easily screw it up, never mind faffing with the burette to balance all the chambers, I realised I had run out of skill/knowledge and most of all confidence (a dangerous thing with die grinders :smash:)

I took the head as it was to Chesman for them to sort out, along with the rest of the engine parts...

[30psi]

Why only remove the squish on the inlet side?

[M.D.]

Why only remove the squish on the inlet side?

id say because he hasnt finished and got scared of damaging anything like he said above,

that squish area removal looks quite neat. i would have just carried on and done the lot,

[Jeffers_S13]

So after our break I re-visited Chesman Motorsport in Coventry on Saturday :Plug: (mention James if you ring :thumbs:) who have been busy doing their bit with our block, head, crank, pulley, clutch, pistons and rods.

Andy was still working on the crank when I got there :

http://i43.photobucket.com/albums/e356/Jeffers_S13/19042008689.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/19042008690.jpg

After a quick nosey around at what else they are up to (some interesting stuff actually :nod:) he helped me lift the whole lot into the back of my Patrol.

Ive only managed to lug the head and crank into the garage so far :

Crank now with lightly polished journals :

http://i43.photobucket.com/albums/e356/Jeffers_S13/21042008711.jpg

and JUN drive collar :

http://i43.photobucket.com/albums/e356/Jeffers_S13/21042008712-1.jpg

Head now sorted out :

http://i43.photobucket.com/albums/e356/Jeffers_S13/21042008710.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/21042008706.jpg

and some top flow work done aswell :

http://i43.photobucket.com/albums/e356/Jeffers_S13/21042008702.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/21042008701.jpg

All the valves need lapping in yet :sleep: and I also want to return to Chesman to give it all a good wash after doing a few more bits and bobs to the block and head.

Will get pics of the block and the other bits when I get them inside, Ive also got to build the spangly new engine stand yet to put it on :smash:

[Jeffers_S13]

Why only remove the squish on the inlet side?

I knew this would cause questions :wack:

There are so many arguments for and against we could be here all day discussing it.

Basically our choice was made by not wanting to lower the compression too much and, as we understand, the exhaust side takes a lot of the heat from the crown of the piston, the pistons have cut outs for the squish areas and almost contact at TDC.

[Jeffers_S13]

that squish area removal looks quite neat. i would have just carried on and done the lot,

I did actually do them all, took me most of a day, but could see that trying to balance them was gonna take me ages and the 13 was here and needing attention for Round 1 so in the end opted to let Chesman do it. I also started to blend the inlet throats. The head is obviously machined to accept the seats and there is some nasty steps immediately under/above the seats and into the throat. I could feel myself starting to get carried away tickling and blending it all back in so I stopped after Id taken the worst of it off. If youve ever done any head work you can appreciate how delicate and time consuming it is.

[Squares]

Looking great mate.:)


If youve ever done any head work you can appreciate how delicate and time consuming it is.


Sooooo true.:nod:

[M.D.]

yeah i can totally understand, ive lost count of how many heads ive ported now and each one takes at least a day to get right, and sometimes a lot more

[David Reid]

Just to add to what Jeffers has said, we were after an engine which wouldn't be det limited on pump (98 ron fuel) at the boost we intend to run . Now others are going to disagree, but its our belief that leaving the squish area on the exhaust side will help us loose heat from piston crown helping to prevent det on pump fuel.

What we have done is exactly what Nismo do on on the Z tune. At the end of the day we wont know whether we have achieved what we set out to achieve until we get in on the dyno.

[lewisj]

so what does the crank polishing do??

[Jeffers_S13]

so what does the crank polishing do??

Just cleans the journals up so they are perfectly clean. smooth and 'nick' free. The crank is totally mint anyway, it had only done ~68k miles.

[paulsx]

Just to let everyone know this project is still running!!!

I have proof!!


http://i16.photobucket.com/albums/b25/paulsx/s15.jpg

Car looks really good in the flesh, quality of the work is first class!!

Should be a real beast!

[Chris B]

Fantastic detailed read... keep it up please guys :)

[lewys14a]

S13 front end looks better on a s15 than a s15 front end.


Awsome project :thumbs:

[Jeffers_S13]

Cheers Paul

Lots done since I last updated this, Ive been planning to update for a while. We have boxes of shiney bits ready and waiting, we have probably 90% of the parts we need now to complete. Dave and I are now working on it pretty much every night and weekend, its very time consuming.

Will sort some updates soon, I have lots of pics detailing everything done.

[Aripug]

Great project.....
one of the best I think
I'm looking to our project and my face is something like that :eek:
Really congratulation for your work
A big ciao
Arian
:)

[Jeffers_S13]

In March and while the unit was still pretty empty we took the opportunity to spray the majority of the car/shell.

Dave and Scott did most of this work whilst I was doing other bits and bobs. I only have a few pics.

Here it is after primer,

http://i43.photobucket.com/albums/e356/Jeffers_S13/04032008538.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/04032008540.jpg

And then starting topcoat

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008543.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008544.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008546.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008547.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008548.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008549.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/09032008550.jpg

[Jeffers_S13]

Subframe and Rear Suspension Assembly

We've been working on the car on and off at the unit over the last few months and buying parts since about last November !

During this time various jobs have been done.

I built the subframe and fitted the solid bushes about three months ago, then we spent an evening getting the subframe onto the car. The solid bushes obviously have no give so the chassis pins had to be sanded with some coarse paper to slightly reduce their OD. The subframe went on with a little persuasion, its nice and tight. The arms are all now poly bushed or rose jointed.

It looks a bit grubby as I used quite a lot of copper slip on threads and fairy liquid to assemble it, the arms and bushes are really tight :thumbs:

Dave fitted the coilovers and brakes, hopefully he has some pics somewhere that I can add.

I have some pics of the fully assembled subframe off the car somewhere so I'll add when I find them...

http://i43.photobucket.com/albums/e356/Jeffers_S13/No_Bush.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/Bush_Fitted.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/Rear_Driver_Suspension.jpg

[Jeffers_S13]

We had a couple of body panels done by a local bodyshop as by the time they were done the unit was full of cars again.

After pushing the car in and out the unit about a hundred times for access and working space we decided that we needed somewhere more permanent to build the car :smash: So about 6 weeks ago we gave it some thought :

Scott's place would have been OK but annoying the neighbours with lots of noise was an issue.

Dave doesnt care about his neighbours :wack: but he only has a small garage at the mo and is mid house-move so not really an option. Which left only the ranch !

We bolted the majority of the body work on for an unissable photo opportunity and loaded the car up and took it back to my place. To make space Ive had to store my Dax at Scott's house for the time being :( it's off the road now for winter anyway.

So here is the car as complete as its going to be until around March next year. Check out the ride height ! Engine will weigh it down a bit hopefully.

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081292.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081298.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081293.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081305.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081300.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081295.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081296.jpg

And where the car currently resides.

http://i43.photobucket.com/albums/e356/Jeffers_S13/191020081319.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/191020081320.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/221020081322.jpg

[Jeffers_S13]

And pics of the boot and fuel cell :

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081303.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081304.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081317.jpg

[Squares]

Looks allwhite!:wack:

[Dunkz]

looking very nice lads, about time you got us a good update. :thumbs:

[Jeffers_S13]

The first thing we did was build another mock engine, the actual engine still isn't built :smash: I will hopefully be starting to assemble it next week. Just waiting on a few little bits now.

So we put the mock engine in the car and then tried the single most expensive component of the whole car for fit and sizing...

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081347.jpg

Shown with a piece of ~3" pipe I was using to check for space for the inlets and outlets and exhaust etc.

Its a twin screw Kenne Bell 2.8H ! Its a monster, as per our cardboard template shown earlier in the thread it fits ~OK. Its an amazing piece of kit, beautiful piece of kit, it'd make a really nice door stop. It was a total ball ache to actually buy. After lots of attempts Dave happened to be nearby on hot test with JLR so in the end literally called in and picked it up and brought it back as hand luggage :D

As you can see its shown resting on some bits of wood and various other oddments used to get it to the correct position whilst Dave sorts out the supports and bracketry needed to hang it off, it is a heck of a weight so it all needs to be pretty substantial.

We have had to invert it to allow a us to route the oulet in a managable direction. It can only be in that plane aswell as the from housing is filled with oil to lube the bearings. It would have been much easier if we could have it on its side, oh well...

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081348.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081353.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081349.jpg

We got a couple of extras with the SC, like an inlet manifold to suit the Mustangs (so no good for us :( ) a outlet clamp plate thing (also no use to us!) some sealant, a relief valve but we also got a shorter drive nose adapter, being replaced/fitted here :

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081339.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081342.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081341.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081340.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/261020081343.jpg

[Jeffers_S13]

I fitted the line-lock valve the other night and started plumbing brake lines in.

Bulkhead fittings in

http://i43.photobucket.com/albums/e356/Jeffers_S13/111120081414.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/111120081415.jpg

Valve fitted

http://i43.photobucket.com/albums/e356/Jeffers_S13/151120081442.jpg

Trusty Flare tool

http://i43.photobucket.com/albums/e356/Jeffers_S13/121120081432.jpg

One short run finished

http://i43.photobucket.com/albums/e356/Jeffers_S13/121120081434.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/121120081433.jpg

[Django67]

*subscribes*

That looks flippin' amazing.

[Jeffers_S13]

I've been sketching and measuring and attempting to sort an exhaust manifold design out fairly recently. Working in the piping industry means we have some fairly useful software here. Having an ethusiastic, car fanatical, CAD driving, work colleague sat at the desk immediately behind me also helps :) he has a registered business and tinkers here and there in his spare time, hence the logo in some of the pics ! he's doing some bits for Fords mostly.

He's done all the CAD work with me poking my nose in now and again and asking him to redo bits...

I measured up for the mating flange first, I have no pics of the CAD model but here is the first 1:1 plot I got. I cut it all out and tried it against the head. A few tweaks here and there and smaller blends and now its bang on. This will be laser cut from 10 mm stainless steel.

http://i43.photobucket.com/albums/e356/Jeffers_S13/051120081393.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/051120081394.jpg

Here are some of the early attempts at a manifold design :

http://i43.photobucket.com/albums/e356/Jeffers_S13/exhaust_james2.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/Manifold2.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/exhaust_9.tif

After this and lots more measuring and double checking it probably wouldnt fit so I got enough info for Paul to be able to model a portion of the engine bay. The green bit is an approximate bonnet line, then there is the engine, the head, the supercharger, the strut brace, passenger turret and the front bulkhead :

http://i43.photobucket.com/albums/e356/Jeffers_S13/exhaust_james.jpg

Then Paul did a few more designs :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Ex-2.jpg

And the most recent and probably the one we are going to make

http://i43.photobucket.com/albums/e356/Jeffers_S13/EX-4.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/EX-3.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/EX-8.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/EX-7.jpg

[Jeffers_S13]

So you may remember we had some fitment issues between the brake servo and the plenum chamber...

http://i43.photobucket.com/albums/e356/Jeffers_S13/13012008269.jpg

So only one thing for it :smash:

http://i43.photobucket.com/albums/e356/Jeffers_S13/171120081448.jpg

Some vigourous hacksawing and die grinding later, along with lots of trial fitting...

http://i43.photobucket.com/albums/e356/Jeffers_S13/191120081454.jpg

Then I made a super tight fitting plate:

http://i43.photobucket.com/albums/e356/Jeffers_S13/191120081452.jpg

Then I got it welded up by a fab shop over the road from work

http://i43.photobucket.com/albums/e356/Jeffers_S13/201120081455.jpg

and hey presto, no more fit issues, obviously we'll need to check how much the engine moves when under hard acceleration and decceleration

http://i43.photobucket.com/albums/e356/Jeffers_S13/201120081456.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/201120081458.jpg

[frisbee]

I've looked at those superchargers before, they integrate so nicely onto a V8, looks a bit more of a challenge on the RB.

Should be a complete beast when its finished. I can see it going through a lot of propshafts, driveshafts and even wheels.

[Jeffers_S13]

I've looked at those superchargers before, they integrate so nicely onto a V8, looks a bit more of a challenge on the RB.


Yes, everything needs to be made to get it to work.

Ive had some quotes for the charger inlet Ive sketched and Paul has modelled...its not a small number :wack:

[liquidsmoke]

This looks great :) I'd love to compound charge a 200. Would be great that.

[Jeffers_S13]

Our car is gonna be supercharged only :) but its pretty potent one.

[_AZ_]

This is art!

[Quail]

This build is awesome! The car is looking great :nod:

[Jeffers_S13]

A week or so before Christmas we assembled a mock engine and mounted any other parts that might inlfuence the shape and design of the manifold and then on one of the least favourable days possible me and Dave loaded the S15 up for a journey to Retford and a small exhaust specialist called OJZ. You may have seen the name in PPC as the owner, Lance, or rather his work has been featured a couple of times.

http://i43.photobucket.com/albums/e356/Jeffers_S13/131220081525.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/231220081553.jpg

We had shown Lance what we wanted using the CAD models and after speaking to him and on his advice we ended up going for 2" primaries ! the model created had been based on 1 5/8" so was only really usable as a general guide. At the flange face they are 1 3/4" diameter, then expanded to the full 2" over a ~5 mm length.

1, 2 and 3 collect and 4, 5 and 6 collect into 2 3/4" secondaries they slide fit into the downpipe sections, and then another slide fit into the collector and a final 3.5" section.

Lance's work is fantastic, he got the manifolds and nearly the full system completed in just over a week. I collected the car in slightly nicer conditions on the 23 rd. It is one of the tightest manifolds he has ever made, the supercharger and the 4" supercharger inlet and elbow (not easily visible, mocked up in HD foam) make space for the exhaust very limited :smash:

You can see an early version of our supercharger mounting bracket in some of the pics.

Pics are better than words so here it is...

http://i43.photobucket.com/albums/e356/Jeffers_S13/201220081545.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/201220081541.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/201220081542.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/201220081544.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/231220081551.jpg

I have a few more pics of the manifolds off the car but I have yet to upload them !

[Jeffers_S13]

Recently I began assembly of the engine. First up I had to clean the block. I got hold of some bicarb media (water soluble and totally environment friendly) and a cheap blast gun.

http://i43.photobucket.com/albums/e356/Jeffers_S13/221120081464.jpg

I blasted as much scale off as I could then rushed the block to Chesman for a quick wash in their hot washer.

I then took it home and whilst there was still some warmth in the block I gave it two coats of engine laquer. Then I fitted a full set of new core plugs, which can be seen in the later pics. This also enabled a through blasting of the water jacket with a high pressure air line.

http://i43.photobucket.com/albums/e356/Jeffers_S13/221120081467.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/221120081466.jpg

Yesterday and at an indicated outside temp of -2.2 degC ! I scrubbed the head face and bores with hot soapy water to remove all of the machining residue. It took three goes before it was totally clean, my hands were almost numb :( But it didnt half come up well. I got through about 5 scotchbrite pads and about 4 knuckles...:wack:

http://i43.photobucket.com/albums/e356/Jeffers_S13/030120091597.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/030120091598.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/030120091603.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/030120091604.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/030120091608.jpg


I then cleaned the crank and the girdle and assembled the bottom end with the new bearings and plastigauge.

http://i43.photobucket.com/albums/e356/Jeffers_S13/040120091633.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/040120091627.jpg

As you can see the clearance is above factory but well within limits.

I began assembling the pistons/rods, I plastigauged the bigends aswell but was halted when I found the ring gaps to be way below the recommended limit. Hopefully Im borrowing a ring filer from exctr so work will recommence very soon !

http://i43.photobucket.com/albums/e356/Jeffers_S13/040120091634.jpg

Bad pic, you can just about see the tiny gap, I can just about get a 0.45 mm feeler gauge in, this one should be nearer 0.6 mm.

http://i43.photobucket.com/albums/e356/Jeffers_S13/040120091644.jpg

[ex-ctr]

i see its moving along nicely, when are you bringing the folder back and i will sort out the ring grinder [not seen it for a while hope i still have it:eek:]

[Jeffers_S13]

I was gonna try and come over tonight but I have a few things to do now as I just bought myself a 180SX this morning and Im collecting it tomorrow ! :sxoc:

How about tomorrow or Wednesday ?

[ex-ctr]

I was gonna try and come over tonight but I have a few things to do now as I just bought myself a 180SX this morning and Im collecting it tomorrow ! :sxoc:

How about tomorrow or Wednesday ?

i lent the grinder out but im finding it hard to remember who to, need to search my pm's:nod:

[Quail]

I forgot how amazing this build is!

[ex-ctr]

found it:thumbs: under the sink:wack: i think my daughter put it away:wack::wack:

[Squares]

Great work alround, good update.:)

Its surprising how many people don't know how to clean a block properly after machining, you are clearly not one of them!

Loving the build, keep up the good work.:)

[Parker]

Just seen the manifold. I think I need to clean my pants :eek: :smitten:

[Jeffers_S13]

Few more pics of the manifolds and full system assembled off the car.

http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091667.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091668.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091669.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091670.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091671.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091672.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091673.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091674.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120120091675.jpg

[Jeffers_S13]

Last night I had chance to start gapping the rings.

First of all, double check what I'd written down...So quick check of the datasheet for the top ring :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Data_Sheet.jpg

Our bore is 3.406. Obviously ours is Supercharged, so,

So 3.406 x 0.0065 = 22thou, which in metric is (x 25.4) 0.56 mm

Select the correct feeler gauges...

http://i43.photobucket.com/albums/e356/Jeffers_S13/Feeler_Gauge.jpg

0.40 and 0.15 makes 0.55 and away we go. I visited exctr last week to pick up his grinder (cheers buddy!) :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Grinder.jpg

I've never had to use one of these before, everyone that has used one has told me they are vicious ! so it took me about 20 goes to grind the first ring. Its a neat gadget. The ring pushes lightly up against the two pins and then you rotate the end gap onto the grinding disc whilst carefully rotating the disc towards the centre of the ring, so burrs are on the inside so as not to damage the cylinder bore.

When you think you've taken enough off or when you want to check how your progressing you just pop the ring back in the bore, levelling it with an up-turned piston about ~1/4" down the bore, thus :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Piston.jpg

Then slot the feeler gauge in :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Feeler_Check.jpg

Weyhey ! it fits, one down...notice the tiny N on the ring, this denotes the topside.

Now the ring is gapped to that bore you need to keep all rings together, I've already numbered the rods prior to assembly, so ring 1 with rod 1.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Rods.jpg

A few hours, a few mugs of tea, a few fags and dozens of trial fits later all the top rings are done.

http://i43.photobucket.com/albums/e356/Jeffers_S13/All_Rings.jpg

It took me all night to do these, but I was terrified of wrecking them so I was uber careful with the grinder. Tonight I'll crack on with the Second Rings...:sleep:

[30psi]

Those manifolds are excellent. Who made them?

[Jeffers_S13]

Those manifolds are excellent. Who made them?

Lance at OJZ near Retford, he's a top bloke :) and fabrication master ! We're very happy with them. The way they slot together is awesome, really satisfying slide fit. We cannot wait till start-up day...

http://www.ojzengineering.co.uk/

[30psi]

Cheers, there work does look excellent, quite impressed.

[TM_S13]

hum...nice job there.
that exhaust mani... sweet

[Jeffers_S13]

Bit more progress made last night. I managed to get the rest of the rings gapped last night, made much better progress without having Dave to natter to :smash::wack:

I assembled the pistons first. I know lots of people have major difficulties getting the pin clips in, here is how I do it. Its a piece of pi$$ really.

First get the rod and pin together and lay it on its side. Put the clip in as so, the open end down into the pin hole, one side will have to rest on the corner/edge of the hole, but the other edge should rest in the tiny machined recess.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Gudgeon1.jpg

Then using both your thumbs (you do have 2 thumbs dont you?) apply even pressure to the bit sticking up, directing it into the hole. Roll your thumbs around the edge and it should quite easily slide into the hole, the tiny machined recess on the edge of the hole stops it spinning around and around, push it in until its like this :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Gudgeon2.jpg

Then using something round that wont mark the piston (I used a marker pen) simply push the clip home until it makes a satisfying clicks into the retaining groove.

Sorry for bad pic...

http://i43.photobucket.com/albums/e356/Jeffers_S13/Gudgeon3.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Gudgeon4.jpg

I assembled all of the rods and pistons first

http://i43.photobucket.com/albums/e356/Jeffers_S13/Rods_Pistons.jpg

Then I fitted all the rings, paying careful attention to the orientation of each gap relative to the front side of the piston.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Built_Pistons.jpg

Then I fitted them to the block using my trusty ring compressor

http://i43.photobucket.com/albums/e356/Jeffers_S13/Fitting.jpg

Liberal use of oil and the job is done :)

http://i43.photobucket.com/albums/e356/Jeffers_S13/All_Pistons_In.jpg

[Jeffers_S13]

Dave is crap at taking pics and recording what he is doing :smash: so here are a few pics :

We are fitting GTS brakes initially, bigger discs means the dustshields foul on them so he removed the hub to get rid of the shield.

http://i43.photobucket.com/albums/e356/Jeffers_S13/No_Dustshield.jpg

We have spacers on the front, they use the standard studs to hold them on, the standard studs need shortening to allow fitment:

http://i43.photobucket.com/albums/e356/Jeffers_S13/Grind_Studs.jpg

Spacer fitted :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Spacers_Fitted.jpg

Whilts Ive been working on the engine, Dave has been adjusting the sump to clear the ARB. So we removed the dummy engine and fitted the new sump and lifted it back in.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Fit_Engine.jpg

Fitted

http://i43.photobucket.com/albums/e356/Jeffers_S13/Fit_Engine2.jpg

By removing the drop links the ARB is free to rotate and Dave can work out where to remove metal from. Some jangle grinding later and some clearance is made.

http://i43.photobucket.com/albums/e356/Jeffers_S13/Cut_Sump.jpg

He has since taken lots more off, so we'll need add on some bits to retain capacity.

Also, just found these pics. Before I cleaned and painted the engine I dressed some burrs and casting lines around the water pump area (the die grinder was out and I got carried away).

Before

http://i43.photobucket.com/albums/e356/Jeffers_S13/Before.jpg

After

http://i43.photobucket.com/albums/e356/Jeffers_S13/After.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/After2.jpg

I also spent some time panelling in the area where the exhaust comes through the car. Thanks again to exctr for the loan of his folder :)

http://i43.photobucket.com/albums/e356/Jeffers_S13/ExhaustPanelling1.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/ExhaustPanelling2.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/ExhaustPanelling3.jpg

[baker_001]

Looks great! :thumbs: When are you targetting to have it done?

[Petrolhead]

This build it amazing! :smitten:

[cliffb75]

Looking good guys - lots of progress :thumbs:

Look forward to seeing it out soon then ;)

[johnpaul200sx]

massive amount of time and work going into the build lads,cant wait to see the end result,keep up the good work.

[Jeffers_S13]

Cheers for comments guys, yes its been lots of work and there is still lots to do. Mapping is booked for about 2 weeks before the first event so it should/must be more or less finished around then. Nothing like leaving it till the last minute...:sxoc:

[Hallsy]

Great project guys, real good show of your engineering skills :nod:

Can't wait to see it finished!

[Tom_w]

absolute work of art.

I'd love a 15.3, I'd love an RB30 bottom end for my 25 and I'd love a supercharger.

Cant wait to see how this ends up.

[a_ahmed]

Very nice project

[s12-newbie]

sweet work here! bet you could appreciated edafs work too!
this will be a cracker when done!

manifold is very nice!!!

your pics have just reminded me i need a to finish an engine build in my garage actually

[Mads B (dk)]

VERY nice !

[Jeffers_S13]

Me again ! :) Lots and lots has been to the car since this was last updated but this is just to show the latest trick part we have had made by people more skilled than us :smash:

Before the car went away for the exhaust at OJZ, we had spent a lot of time thinking about routing the inlet and outlets of the charger. The charger inlet is on the very back and the outlet is on top (normally underneath but we are mounting the charger upside down). The challenge was to get air to the inlet obviously as smoothly and efficiently as possible. I had a rough idea what we wanted (or rather needed) it was pretty much dictated by what space we might have. I asked a guy at work to draw up the shape we were after so we could better visualise how it would look.

http://i43.photobucket.com/albums/e356/Jeffers_S13/chargerinlet1.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/chargerinlet3.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/chargerinlet4.jpg

This was imported into the engine bay model we already had and tried on the supercharger for fit against the exhaust model, before any metal was even cut !

It was clear that the inlet pipe part would have to be offset slightly to avoid the exhaust headers, so Paul made the mods to the model and then we settled on a slightly offset design. To allow Lance at OJZ to haev something to work around we decided that a mock-up of the inlet would be needed so we bought some foam insulation and Dave set abotu making a right fcuking mess in my garage :whip: cutting it up and copying the pics Blue Peter stylee :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_Model.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_Model1.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_Model2.jpg

So this is what went with the car and charger to OJZ, you can see it in some of the pics in those posts.

So now left with the challenge of making this, I considered making it myself, Ive done some metal bashing on various other projects but imagined it would be a right headache doing something as complex as this, i.e bending in 3 planes through very tight curves. So I contacted a few rapid protyping places and a place that do one-off castings. The prices were just too high to justify.

[Jeffers_S13]

Literally across the road from where I work is a place called Shapecraft

http://www.shapecraft.com/ :Plug:

They are a proper metal bashers, they do one off full aluminium bodies for specials and also do full body restorations of Astons, Ferraris Austins etc they also make a lot of prototypes for Triumph who are just up the road from my office. Ive used them for ali welding in the past and various other odd jobs where I wanted some good quality welding. I paid them a visit with some drawings and the model Dave made. After some joking around Darren, the foreman, quoted a very fair price.

I got Paul to do me an accurate flange drawing using some of the extraneous parts we got with the charger for dimensions. I had one cut out of some thin plate to make sure it fitted then after a few tweaks had the final part cut from 10mm aluminium. No pics of it on its own :(

I visited Shapecraft with the bits and left it all with Darren. Just yesterday I returned to see how they were getting on, I was amazed !

If anyone has ever tried making stuff Im sure you will appreciate the years of skill that you need to be able to do a proper job like this ! Clearly this is just a roughed up first effort, its only tacked together so we can do some trial fits but I'm amazed with how closely the part resembles the model :notworthy

Here it is attached to the scruffy looking taped up charger :wack:

http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_First_Go8.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_First_Go10.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_First_Go11.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_First_Go13.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_First_Go15.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/Inlet_First_Go16.jpg

So now we just need to make 'Charger Mount - MkII' as MkI was slightly damaged in a rope-snapping-type-dangling-engine type incident, but we wont go into that...then we can fit the whole lot and see how good the fit is then tweak as necessary and return it to shapecraft to finish it off.

Lots more work/progress to post ! I will get around to it eventually.

[dano]

now that is nice work

[ex-ctr]

i must pop around to have a look, is it at your unit:)

[Jeffers_S13]

i must pop around to have a look, is it at your unit:)

Nope, it's at the ranch :) Just come round any evening or any weekend, we're working on it all the time at the mo :smash:

[ex-ctr]

Nope, it's at the ranch :) Just come round any evening or any weekend, we're working on it all the time at the mo :smash:

next weekend if poss, this weekend im working:( :thumbs:

[Matt_S]

Hahaha! Be careful with that new pipe James!

[TF&TF]"You might crack the welds on the intake!"[/TF&TF]

PMSL :D

Nice work all :thumbs: :)

[30psi]

Cool stuff

Will you be ok to get a bolt in the top there?

[Jeffers_S13]

Cool stuff

Will you be ok to get a bolt in the top there?

Trust you...nobody was supposed to notice that :o

Answers on a postcode or the back of an envelope to...

If we cant get one on, its not the end of the world, there may be a tiny gap air can get through but it wont affect things. The two each side and the gasket might seal it enough

[Jeffers_S13]

Hahaha! Be careful with that new pipe James!

[TF&TF]"You might crack the welds on the intake!"[/TF&TF]

PMSL :D

Nice work all :thumbs: :)

It's the checkerplate floor Im worried about :smash: but I'll my eye on the welds...:wack:

[Matt_S]

It's the checkerplate floor Im worried about :smash: but I'll my eye on the welds...:wack:

Buy my car as a spare then - just in case, like :wack:

:D

[Parker]

Clever stuff :D Even more clever to get that bolt on :smash:

[M.D.]

thats some really nice fabrication,wouldnt like to have to do that top bolt up though lol,

[cliffb75]

Cool stuff

Will you be ok to get a bolt in the top there?

Thats why god invented studs and nuts :)

Very trick looking part. Will look good when its finally shaped and polished.:nod:

Any pics of progress on the shell or engine build then?

[Jeffers_S13]

Thats why god invented studs and nuts :)

Very trick looking part. Will look good when its finally shaped and polished.:nod:

Any pics of progress on the shell or engine build then?

Yes, stud and nut is the potential solution, but it might only be a couple of threads and very slim nut, I might see if the fab shop can put a small blister in there somehow to get us a tiny bit more room to twirl a spanner. The standard inlet we got with the charger comes round from the side to suit the V8 it's meant to go on, ours isnt quite as easy as that.

There are few engine pics a few posts back, Scotts been cleaning all the valve gear tonight ready for me to start assembling the head tomorrow night hopefully for a first go at shim checking. The bottom end is all wrapped up ready and waiting for it.

As I said, we've done loads more, it just isnt documented yet. All the brake lines are now complete and plumbed in, extinguisher and emergency pulls are done, the plenum and hosing to and from the intercooler are getting there. We borrowed a rivnutter off Max, so Ive been playing with that on the exhaust box and pretty much anywhere else I could find to make use of it, they're brilliant. I picked up Daves revised charger mount bits, which he spent a lot of time designing, from the laser cutters yesterday ready for him to assemble and weld up. I sorted the timing ring gear out and also got that cut recently, this bolts to the front of the charger drive pulley which I also designed. All those bits are away at the mo at a place called Transdev in Poole who are making the charger pulley. After several evenings of debating and arguing we sorted and agreed upon the fuelling system layout/design and Dave went to Earls yesterday and came back with a box of bits and a very big bill :wack: So I've been laying them in the car tonight to check we have all we need, got lots of pics will upload soon, I just need to find a bit more time and write some words !

There is lots still to do so I'm beginning to get stressed now :)

[ricey]

truly awsome project:clap:

just read the full thread:cool:

[milez]

Same here just read all 10pages. Amazing build up thread guys:thumbs::thumbs: Hope you manage to get it finished and up and running soon:)

[Adams]

Damn this thread is fun to read!!! Awsome project :nod:
Keep up the good work :thumbs:

[swiftmini]

awesome project

[Jeffers_S13]

Another update. We’ve been very busy with the car since about January now, we are spending every evening on it and weekends aswell and I’m not really keeping this thread up to date…

Some time ago Dave started to think about how the charger was going to be mounted. You can see some pics of the first effort earlier in the thread, here’s how it looked :

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091872.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091873.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091874.jpg

The positioning of the charger is obviously determined by the position of the drive pulley on the crank. After some careful measuring the postion was roughly decided by resting the charger on bits of wood and using straight edges to estimate what the drive pulley would be. Then lots of measuring and cardboard mock-ups were made to try and decide on the best way to mount it. Dave did some sketches of the first idea and I took them to work for Paul to draw up. I supplied the resulting drawings to a fabrication shop called ‘Target Fabrications’ in Barwell, just outside Hinckley. Scott will cut stuff at the drop of a hat and is very reasonable on price. All the plates were 3mm mild steel in this design. This mount was used to support the charger whilst it was away at OJZ having the exhaust made and it since suffered a slight prang when we were lifting the mock engine in and out ! hence the bent part. You can see how it has been modified a little to fit the block and the charger snout. The small stanchions on the back allow bolts to go through and into the front plate of the body of the charger.

After a few alterations and a rethink Dave changed the design so greater support could be offered, Paul modified the original drawings and produced new ones for the new parts, this one is made from 4mm mild steel, this is Mk II

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091870.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091869.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091871.jpg

A few further changes and slight refinement and also now with the incorporation of parts to allow a belt tensioner, this is Mk III. Again in 4mm mild steel.

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091888.jpg

Notice the slot to the side of the charger snout hole

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091887.jpg

This allows another part to be perfectly aligned with the edge and also helps assembly.

This idea repeated where the base plate slots through :

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091883.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091892.jpg

Some more showing Dave’s welding !

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091890.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091882.jpg

[Jeffers_S13]

The charger unfortunately sits right where the PAS pump would normally go. We have considered several options to allow PAS and decided that retaining a standard pump was the safest and one of the easier/cheaper options.

Dave has designed some additional brackets to support the PAS pump immediately below the charger. Again the position of the this is dictated by where the drive pulley is located on the crank. By some careful thinking Dave has also retained the original tensioner arm. These pics don’t really show it very well so I’ll take some more at some point and add them to this post.

Brackets :
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091916.jpg

And finally the charger mounted to the engine with the PAS pump beneath it. You can also see the tensioner parts along side the charger snout. Again I’ll add some more pics when I get them with all the belts on.

http://i43.photobucket.com/albums/e356/Jeffers_S13/090320091921.jpg

[Jeffers_S13]

To drive the charger we obviously need a pulley on the crank. We want to drive the charger at approximately twice engine speed. We got two drive pullies with the charger so we have gone for a diameter that suits. Again lots of head scratching and thinking in terms of what we wanted ensued ! The thinking seems to burn most of the time on this project, the actual making is relatively quick.

We had already bought a proper damped crank pulley that had tapped holes on the front to allow fitment of addtional pullies :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Crank_Pulley.jpg

So, this decided how the charger pulley would be mounted. Aswell as the additional charger pulley we also needed a trigger wheel for the engine management. I decided to try and incorporate the two but there were lots of constraints and factors that affected how it would need to be (too many to go into here !)

After looking through what was available (mainly on www.trigger-wheels.com) none really suited our needs.

So I drew up what we needed and yet again called on Paul to do me the drawing. I sent it over to Target Fabs again for it to be cut, the next day I collected it :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Timing_Wheel1.jpg

Our requirement for the crank charger pulley was very specific to our needs. As you’d expect this isn’t an off the part shelf available from anywhere. So after some phone calls to find someone local that could help us we failed…for some reason very few places are able to turn pullies with Automotive type V’s ? I finally found a place in Poole that could make us what we needed call Transdev. Really friendly bloke called Chris has helped me out during this. After a lot of discussions and various iterations this was the final drawing we came up with (again penned by Paul) :

http://i43.photobucket.com/albums/e356/Jeffers_S13/Drive_Pulley.jpg

Paul drew it up and I sent the crank pulley and trigger wheel down to Transdev. I decided to have the new pulley made to perfectly suit the trigger wheel and crank pulley.

Three weeks later the new pulley arrive :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091938.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091939.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091940.jpg

It is the most lovely piece of kit we’ve had made so far even if I say so myself :smash: Really impressed with the quality. It slips over the crank pulley beautifully and the trigger wheel slips just as smoothly over the crank pulley.

It assembles in this order, crank pulley :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091941.jpg

Charger pulley

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091942.jpg

And trigger wheel :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091943.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091944.jpg

[Jeffers_S13]

More recently I continued with the engine build. The next step was to build the head. I spent a whole weekend building and stripping and checking and adjusting the shims to get the correct clearance under the cams. Scott had spent several evenings getting nasty blisters lapping all the valves in.

Kit of parts :

http://i43.photobucket.com/albums/e356/Jeffers_S13/010320091851.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/010320091854.jpg

Before I put the cams in I cleaned up the cam cap threads. I’ve seen quite a few thread now about stripped and sheared cam cap bolts so its well worth doing to ensure there is no debris or oil in the threaded holes that might cause lock-up before the bolt is properly home.

http://i43.photobucket.com/albums/e356/Jeffers_S13/260220091850.jpg

When the head is assembled and the cam caps are torqued down (in the correct sequence of course :smash:) the cams are rotated around freely and the gap between the cam and follower measured. I had to modify a set of my feeler gauges to do this as I don’t have any cranked ones 

http://i43.photobucket.com/albums/e356/Jeffers_S13/Modded_Feelergauges.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/Head_Assembled.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/Feeler_Under_Cam.jpg

All but three of this head were fine. I carefull ground the shims smaller (by 0.1mm) and re-assembled and re-measured. All OK this time.

So yet again I stripped it all down ! yawn !

http://i43.photobucket.com/albums/e356/Jeffers_S13/260220091846.jpg

Then I fitted the new stem seals :

http://i43.photobucket.com/albums/e356/Jeffers_S13/240220091820.jpg

This is how I do it :

Slide stem seal onto narrow long screwdriver :

http://i43.photobucket.com/albums/e356/Jeffers_S13/010320091855.jpg

Then slide down onto the guide, withdraw the screwdriver and then use suitably sized socket (resting on the outer edge of the seal) to press/push firmly onto the guide.

http://i43.photobucket.com/albums/e356/Jeffers_S13/010320091856.jpg

Before putting the valves in for the final time I also oiled the stems. obviously all other mating surfaces had copious amounts of assembly lube applied.

http://i43.photobucket.com/albums/e356/Jeffers_S13/020320091859.jpg

[Jeffers_S13]

We hadn’t as yet measured our final compression ratio so at this point we decided to see what it was !

So I made a perspex plate and fixed it to the head face with grease :

http://i43.photobucket.com/albums/e356/Jeffers_S13/040320091860.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040320091861.jpg

Then using a burette filled with paraffin we measured the combustion volume :

http://i43.photobucket.com/albums/e356/Jeffers_S13/040320091862.jpg

Our combustion chamber volume is 65.5 ml.

After lots of sums accounting for piston crown, stroke and head gasket etc we determined that we have a ratio of approximately 8.1 : 1 which we are happy with (maybe a little higher than we would have liked).

Happy with this I proceeded to fix the head to the block.

We bought the headgasket along with a massive box of other parts from RHD Japan. We have gone for a 1.8mm Tomei metal gasket :

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091905.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091906.jpg

First off thought I put a bung in the oil feed as a result of noticing Hexham Scottys unfortunate problems

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091895.jpg

Then I put the head studs in, plenty of Moly grease and finger tight into the block :

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091896.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091898.jpg

[Jeffers_S13]

Then I laid the headgasket on :

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091910.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091911.jpg

As you can see I had already attached the new water and oil pumps, again I cleaned all the threads prior to assembly

http://i43.photobucket.com/albums/e356/Jeffers_S13/140120091701.jpg

Super expensive JUN oil pump :

http://i43.photobucket.com/albums/e356/Jeffers_S13/121120081428.jpg

All attached

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091893.jpg

With Dave’s help I laid the head onto the block. Then I torqued the studs down in three steps, 4 times ! as per ARP guidelines.

All finally done :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100320091930.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100320091931.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100320091932.jpg

[Jeffers_S13]

Most recently I have been working on the inlets and outlets and plenum chamber. As shown previously the inlet had been fabricated for a first fit and tacked together. A few small adjustments were needed so I took it back to shapecraft and they altered it accordingly.

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091945.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091946.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091947.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091948.jpg

To get the outlet to where it is needed I cut off the end and with some 4” bends made some pretty elaborate addtions.

New 4” bends :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091957.jpg

First stage of additional sections :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091966.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091965.jpg

The pics don’t show the exhaust manifold but not only do I have to miss that but also the outlet from the charger (not yet modelled). The outlet has to meet up with the hose leading to the intercooler making things very tight. So an additional piece of 4” bend carefully cut to suit leads it further into the inner wing area. Based on the remaining space we have selected a candidate for the air filter from the substantial green cotton air filter range. I made a mock up of it from card to make sure it fits (not shown in the pics).

http://i43.photobucket.com/albums/e356/Jeffers_S13/150320091968.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/150320091969.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/150320091967.jpg

[Jeffers_S13]

On the plenum chamber side, I had already begun positioning of parts. When the throttle body is positioned on the end of the plenum it fouled the bonnet so some adjustment was needed. Rather then modify the bonnet we decided to add a curved portion to the plenum chamber.

The opening to the plenum was 3.75” the throttle body is only 3.5”. So it needed a tapered bend, hmmm, yet another part you cant actually buy. So We got some 3.5” tube and a attempted to cut and shut a mitred bend onto the plenum, not very easy. So in the end I just cut the pipe to suit and handed it to Darren at Shapecraft…

He got the welder to tack the pieces together so I could try it…

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091952.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091953.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091951.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091950.jpg

A pretty good first effort, so this piece is just awaiting final welding and shaping. I also cut another small section from the back of the plenum chamber to clear the clutch master cylinder.

http://i43.photobucket.com/albums/e356/Jeffers_S13/100320091927.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091954.jpg

And I also got a plate made and welded to the cam pulley cover to cover the hole where the CAS usually goes.

http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091875.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091877.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080320091879.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091958.jpg

[Pablo13]

Some great fabrication going into this car, keep up the good work guys :thumbs:

[Scotty_s13]

This is an awesome project keep up the amazing work..

[minwaash]

looking good :cool:

[Parker]

Stunning work :clap:

[dread]

Such a high level of workmanship going into this... I just wanna hear the sound it makes :wack:

Truely inspirational build

[ex-ctr]

i must find time to see this in the flesh, great design and implementation and with a supercharger will have massive low down grunt:nod:

[cliffb75]

looking :thumbs:

[Rich_M]

Inspired!:nod:

[downshift2drift]

do you still have the door wiring harness? an do you need them?

[MarkeyB]

WoW

[Lee75]

some amazing fabrication and welding going on there any updates:)

[Dal]

Awesome fabrication work :nod::thumbs:

[tomo1]

Yep- This looks like a properly designed beastie!

[Jeffers_S13]

Thanks for comments ! :sxoc:

Will be some updates very soon, we have literally just spent the last 14 days solid working on it ready for mapping. 16hr days and some very late nights, very little sleep and a million pics to upload.

Here is a teaser pic of it on Emerald's / Dave Walker's RR yesterday...oh dear, I uploaded a pic where you can't see the engine bay very well ;) :p

http://i43.photobucket.com/albums/e356/Jeffers_S13/150420092255.jpg

I will get round to a load of proper update threads tomorrow night. We're having a couple of nights off to recover :)

[800bhp]

Glad to see you made it to mapping on time, well done :thumbs:

[Lee75]

You big tease :whip:

[ricey]

tease

i require pics now:smash::smash::smash::smash:lol

[Squares]

Wow, you must have worked pretty hard to get that to mapping so quickly! I look forward to the updates.:)

[dread]

:cry:I wanna see

[CNHSS1]

Here is a teaser pic of it on Emerald's / Dave Walker's RR yesterday...oh dear, I uploaded a pic where you can't see the engine bay very well ;) :p

http://i43.photobucket.com/albums/e356/Jeffers_S13/150420092255.jpg

Bloody hell :eek: Daves had a tidy up and moved his 'Ol ducati and the turbo 924 on E85! see his westys now filling the space. the old Festa Hot Hatch i still there i see, dont think its moved in years

Top bloke though Mr Walker :notworthy

bet your proj interested him, likes weird and wonderful stuff doesnt he? :)

[Si]

Wait, you've converted it to a rear beam setup? :confused:



Ah hang on, it's the one in the background, isn't it.

Awesome news guys! I need to buy some sh!t off you so i can have an excuse to come round and see it :D

[Jeffers_S13]

Bloody hell :eek: Daves had a tidy up and moved his 'Ol ducati and the turbo 924 on E85! see his westys now filling the space. the old Festa Hot Hatch i still there i see, dont think its moved in years

Top bloke though Mr Walker :notworthy

bet your proj interested him, likes weird and wonderful stuff doesnt he? :)

924 is outside, his GTi turbo is the one on the ramps at top of pic. Yes, Festa on the right and Westie in front of it. He was quite interested and keen to help with a few small niggles we had with it. He is sound as a pound and very patient !

[Jeffers_S13]

Wait, you've converted it to a rear beam setup? :confused:



Ah hang on, it's the one in the background, isn't it.

Awesome news guys! I need to buy some sh!t off you so i can have an excuse to come round and see it :D

Yeah call round if you want, anyone local is free to call in, we'll be on it all weekend again, slightly less stressed than recently. Just give me a bell to confirm we are actaully there.

[dammit]

So is it going to be ready for Oulton Park? please say yes please say yes please say yes please say yes

[Ian200sx]

PPC mag feature surly?

[Jeffers_S13]

Right, where did I get to...

I'll start with the sump, this was one of the things Dave did. As you may remember a while ago Dave had spent a long afternoon hacking bits off so it would clear the front ARB and then we had lifted the mock engine back in to double check clearance, thus :

http://i43.photobucket.com/albums/e356/Jeffers_S13/040120091637.jpg

Well he didnt stop there :cry: having now cut a load of it away at the front, it had obviously lost some of its capacity. Some sums and geometry later and deciding how much oil capacity we wanted meant extra wide cheeks were the only way to allow us to retain the capacity we wanted (8.5 litres) so even more came off and it ended up looking like this :eek:

http://i43.photobucket.com/albums/e356/Jeffers_S13/310320092012.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/310320092013.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/310320092014.jpg

Hmm, one expensive sump that is now no good...

Dave worked out the shape of the cheeks to clear all the other stuff to the sides of the sump area and after a quick trip to the metal supermarket returned with various sheets of steel ready to fold and weld up.

Annoyingly I'm gonna have to jump to the final result now as he is sh!t at taking pics ! and forgot to take any during the assembly and fabrication stage :rolleyes:

Dave did all the fabrication and welding and it came out like this :

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092047.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092038.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092037.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092036.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092034.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092033.jpg

[Jeffers_S13]

Then I bought a shed load of paraffin and Dave filled it with 8.5 litres to check for no leaks, there weren't any ! :thumbs: Also this enabled him to sort out the dipstick and adjust one to suit the new levels.

http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092053.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092054.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092052.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092050.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092051.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092146.jpg

Then some more adjustments to various bits and welded the sump adapter on. I also made up a sump adapter on one of Chesmans lathes to allow us to fit an oil temp sensor, just about visible in one of the pics.

Then we fitted it back to the mock engine and double checked it still fitted :wack:

http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092057.jpg

It was then ferried around various places, first to the powder coaters for a good grit blast, then it was painstakingly cleaned by Scott and the airline, then Scott took it to Chesmans and used their hot wash and parts washer. It was then taken back to the powder coaters and it came back like this with some other parts :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092117.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092116.jpg

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092121.jpg

[Jeffers_S13]

I took the inlet with the taped up 4" bends, as shown earlier in the thread, back to Shapecraft and Karl tacked it together for some more trial fits. After I was happy it fitted OK they fully welded it and put a swage on the end, Scott polished all of the shrink marks to make it look presentable.

Here it is after I got it back from Shapecraft. The big cut out from the underside is to clear the outlet.

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092168.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092169.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092170.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092171.jpg

Before finishing the inlet I started to work on the outlet from the charger. I didnt take many pictures of the outlet build process unfortunately. It basically followed a similar process as the inlet.

First of all I asked Paul to do me some mock-ups in the CAD model so I could sort of work out what shape it was gonna need to be.

http://i43.photobucket.com/albums/e356/Jeffers_S13/inlet1.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/inlet2.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/inlet4.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/inlet5.jpg

First of all I sketched the plate I needed to allow attachment to the top of the charger. Paul quickly drew it up in CAD and I sent it to Progress Fabrications in Warwick to be laser cut.

Space yet again likt the inlet was tight and dictated by stuff around it, mainly the exhaust manifold and the inlet. I made a foam model and again took it to Shapecraft where Darren and Karl worked there magic and made one in aluminium. A few back and forth runs with it for fettling and finishing until it fitted, I also asked them to put a swage on the very end to keep the silicone blister joiner on when under boost.

Again Scott then spent some time polishing it up and here it is :

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092191.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092192.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092193.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092189.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092190.jpg

Here they are fitted to the charger in the engine bay :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140420092242.jpg

[Spence]

Some amazing fabrication going in to this - top job :thumbs:

[M.D.]

amazing work, but if its down dave walkers that must mean that its running :) more more..............

[Karan]

Nice work guys

[Jeffers_S13]

Another installment, car is actually running but I want to write the thread in a chronological order !

I continued with the fuel system over the period we had off around Easter. A while ago we had thought about the fuel system a lot and decided that overkill was better than err underkill. So we sketched some layouts, had some arguments, made some decisions and then went online to order the bits. We already had the fuel cell and that was more or less decided where it was going. We went for three 044’s, inline filters, braided hose and Earls fittings throughout, regulated by a genuine SARD FPR. Our first design had the lines running through the car, this meant a lot of bulkhead fittings and a lot of bends and stuff, the bill was over £2.5k…hmmm, we then had a re-design :wack: we decided to route the lines under the car to reduce the number of fittings, it also meant the inside of the car would look neater and less cluttered, the bill was also reduced :thumbs:

This is a small collection of bits we amassed before starting the plumbing :

http://i43.photobucket.com/albums/e356/Jeffers_S13/250220091844.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/250220091845.jpg

We also had filters on the way. The pumps and FPR were bought from a trader on ebay and the one-way tank breather valve was bought from Think Auto.

Close up of a sexy 180deg bend

http://i43.photobucket.com/albums/e356/Jeffers_S13/250220091838.jpg

One of the pumps

http://i43.photobucket.com/albums/e356/Jeffers_S13/250220091843.jpg

We did look online and found most of the fittings for a lot less money but the delivery and import tax actually made them almost the same overall price.

We naturally wanted/needed a surge tank. After being inspired by pics on the net, I had a go at surge tank design, We wanted the feed and return lines under the car so to reduce the number of bulkhead fittings they went on the underside. The tank is baffled and its capacity is about 6 litres. Paul again drew it up on the CAD kit at work and the drawings were sent to Alifab for construction, here it is :

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092041.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092042.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092043.jpg

Frickin amazing welding skillz and weld on fittings for underside connection.

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092044.jpg

[Jeffers_S13]

The boot floor was already complete and ready to go as shown in previous pics :

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081304.jpg

Fuel cell :

http://i43.photobucket.com/albums/e356/Jeffers_S13/181020081317.jpg

First of all I had to fit the breather valve to the tank which meant taking all the filler neck off, taking all the foam out and drilling a new hole in the cell !

Done

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092028.jpg

I modified the tank supports some time ago and had them powder coated. The cell needed to be supported off the floor due to the sump where the outlets are, so I just added some short stanchions to the bottom.

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092031.jpg

Fitted with surge tank

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092049.jpg

So, the general system consists of :

044 feeding surge tank via -6 hose, with inline prefilter, fed by -8 hose from tank
Twin -8 feed hoses from bottom of surge tank to twin 044’s feeding double ended SARD fuel rail through -6 hoses.
Single central -6 to SARD FPR
Single -6 return to surge tank
Single -6 overflow from surge tank to cell.
Single -6 breather via one-way valve to atmosphere outside fuel compartment.

I started at the back and worked my way forwards. 044’s must be gravity fed, forcing them to suck is bad for them. I mounted the feed pump for the surge tank immediately behind the cell as shown :

http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092055.jpg

The two feed pumps are mounted on the underside of the car, one each side of the fuel cell recess, I have pics but cant seem to find them :mad:

[Jeffers_S13]

To make the hoses was initially a bit of a PITA but as I progressed I actually found it quite therapeutic ! First you do a fairly accurate measurement of the hose length needed, then wrap the cut area very tightly with insulation tape :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092126.jpg

Mount in a vice just tight enough to hold the hose without it falling out. Then I found that a super thin disc in a side cutter on a very high speed setting did quite a good job cutting the braid.

Action shot !

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092129.jpg

Then I cut and trimmed the rubber hose part with a sharp knife till you end up with this :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092130.jpg

Note how there is no fraid braiding, initially I just could not stop it from fraying, I found wrapping it tighter helped and a saw is totally frickin useless for cutting, despite what the guides say, especially on the smaller bore stuff, this is one of the oil lines I’m showing here, so its real big -10 stuff. Note the cut must be square and clean.

Then carefully unwind the tape and thread it into the fastener. This can be a real PITA, the small the bore hosing the harder it seemed to be, the orifice it has to go into seems smaller than the OD of the braided hose. I found carefully twisting it on did the trick, its wound on till it almost reaches the threads.

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092132.jpg

Then you oil the fitting you are using,

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092135.jpg

and push it in and jangle till a thread engages, then you wind the hose part onto the fitting using a couple of spanners or a vice and spanner. The guides say to wind will the fitting almost touches the fastener but I found this to be very tight and at risk of stripping the ali threads I wound till it felt tight, none of them have leaked so far.

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092134.jpg

Job done.

I had to do this dozens of times and got quite good by the end :)

Here is the hose that goes from the cell to the pre-filter on the feed pump, this was the first one I did.

http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092059.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092061.jpg

And fitted :

http://i43.photobucket.com/albums/e356/Jeffers_S13/050420092062.jpg

[Jeffers_S13]

We bought some cool mount brackets for the pumps but we wouldn’t find any to suit the filters. So I brought one into work with a filter and asked Paul to scale it down. Then I sent the drawings to Progress to have one cut from ali, the pump ones are clearly cut from an extrusion but we had to have ours cut. We had some cut from steel as the place we use couldn’t cut ali this thick, they didn’t look very good so a machine shop Dave had been using for some other parts, yet to be mentioned recommended Lightening Aerospace just outside Coventry. They can water jet cut 150mm stainless plate ! so our little brackets were no probs. I emailed the drawings over and a week later went to collect them :

http://i43.photobucket.com/albums/e356/Jeffers_S13/090420092111.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/090420092114.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/090420092112.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140420092232.jpg

Not cheap, but they look cool !

So anyway, after hours and hours of work, some very sore fingers I completed installing the fuel lines. All p-clipped at least every 200mm.

http://i43.photobucket.com/albums/e356/Jeffers_S13/140420092235.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140420092236.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140420092238.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/140420092233.jpg

Use of rivnuts again ! brilliant things.

http://i43.photobucket.com/albums/e356/Jeffers_S13/060420092080.jpg

Got loads more pics somewhere but cant find them, so will add to this post when I do.

[Jeffers_S13]

I did find these pics though. We are trying to decide what car to use as a basis for our next project. Cliff (of mad minor fame) happened to be out and about in this, so he called in to let us give it the once over...;)

http://i43.photobucket.com/albums/e356/Jeffers_S13/430f.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/430g.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/430h.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/430d.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/430ee.jpg

We 'ummed and arred' a bit much for Cliff's liking so a few days later he rocked up in this...the reason he had the 430 to mince about in. Excuse the pic quality, taken by my female housemate who was too busy screaming with excitment about being taken out in it. This is actually one of the development cars and has the right number of cylinders :D Cliff is working on this project at the mo so he HAS to drive it around on a regular basis just to make sure its ~OK, what a $hitty job :rolleyes:

http://i43.photobucket.com/albums/e356/Jeffers_S13/107_0458a.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/107_0459b.jpg

Me and Dave are undecided as yet, but the R8 doesnt half shift and tail out fun is quite easy to induce...and it feels like you could do an endo the brakes are so good, when Cliff demonstrated them the car thought it was doing an emergency stop and put the hazards on automatically :smash:

[Quail]

1. Cliff is a bastard.
2. Theres some awesome fabrication in this thread!

[Petrolhead]

Theres some awesome fabrication in this thread!

:nod: amazing work

[CNHSS1]

1. Cliff is a bastard.
2. Theres some awesome fabrication in this thread!

:clap: proper funny

[Jeffers_S13]

This is gonna be a fairly short post as, as per usual Dave didn’t take many pics :annoyed::smash:

We originally intended on using some brackets we bought from a place in the US. They have MGM etched into them and we got engine mount bracket and gearbox mount bracket. They mounted the engine right at the back of the bay and very low. However they were fairly thin and not made that well, and generally didn’t look up to the job of holding in an engine making XXXBHP. So we used them until we finally got around to making something more substantial.

http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092196.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092197.jpg

I measured up what we needed and had some parts made from 4mm mild steel, laser cut by Target Fabrications, near Hinckley. Basically consisting of a plate that extends forwards from the original subframe mount hole, then two triangular-ish gussets that then slot underneath. No pics of them unfitted or un painted :rolleyes:

We also intended to use Nismo mounts to restrict engine movement, but as the engine bay became more and more cluttered and various parts like the exhaust manifold and the plenum were within ~10mm of the inner wings we decided that more or less solid mounts might be the safer option.

Dave found a place online selling cusco style mounts but with even less give. They are a modular design and can be dismantled. Again no pics of them un-fitted.

Here are pics sort of showing the new brackets and the new mounts in situe, before and after painting etc.

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092154.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092156.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092153.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092152.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092149.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092148.jpg

And we have the ~solid gearbox mount aswell, but there are no pics of that at all ! :wack:

[Jeffers_S13]

So whilst Dave was working on the wiring (yet to be covered here) I was doing other stuff. One job I did was to plumb and mount the remote filter/thermostat plate and cooler. This kit came with the S15 shell when we bought it, literally years ago now ! so that’s why it looks 2nd hand…

All the hoses were the wrong length so I had to measure and adjust each one in turn. Also to attempt to limit the amount we have spent on this project (ha!) I had to work out how it could all be fitted without having to buy any more Earls joints, -10 joints are uber expensive. I managed to use do it with all the original fittings just by swapping them around and matching them up with how I wanted it to fit and it almost looks like I selected them as I think it fits quite well, probably not exactly how I would have wanted it but it's OK.

Scott first cleaned everything up as it was covered in slimey grime amd a film of oil.

Take off plate :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092123.jpg

Remote thermostat filter block.

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092122.jpg

Block mounted (hmm not looking forward to changing the filter) :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092136.jpg

All hosing after many hours work and faff

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092137.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092138.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092139.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092140.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092141.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092142.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092143.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092144.jpg

Again, I can’t seem to find any pics of the cooler, will try and take some and then add.

[Jeffers_S13]

Finally all the dirty and messy fabrication work within the engine bay was complete and it was time to fit the real engine. It had been patiently waiting its new home for some time on the stand since I built it.

http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091992.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091991.jpg

We lifted it off the stand and Dave fitted the new rear crank seal and the new bush (old one removed using the effective, if messy, grease method) whilst I hunted for the clutch…

Aha, it had also been patiently waiting its turn in a box under the bench. I dismantled it all and gave it a quick clean and blow over with the airline.

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092160.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092161.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092163.jpg

Note how much was removed from the cover plate when being balanced, also tiny amount taken from the flywheel aswell.

We also took the opportunity to fit a new Nissan release bearing.

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092167.jpg

To hold the assembly from rotating whilst the flywheel bolts were done up we made up a make-shift clamp.

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092162.jpg

All fitted

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092164.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092165.jpg

[Cloudy]

You've done such a neat job on the fuel cell arrangement etc, very impressive.:notworthy

I don't like Cliff.

[cliffb75]

Like Jeffers says, its a $hitty job, but someone has got to do it :cry::D

Anyway, enough about my hard life, this is about the PPS drift car! Having seen it in the flesh (and heard it running ;)) I have to congratulate the chaps on an awsome job. The amount of effort that has gone into this build is quite incredible - it seems like nothing has come easy, but the guys have always made sure that problems are dealt with the 'right' way, rather than by bodging or making do, which is why there are so many one off bits and fantasic fabrications.

After all that effort though, how will you feel when Scott goes out there and thrashes it senseless in the name of entertainment :eek:

Shame you didn't make round 1, but keep up the good work and we'll keep our fingers crossed for you :nod:

[Jeffers_S13]

Thanks for all the comments guys, much appreciated. We aren't doing this just for ourselves, most people who see the car and engine cant wait to hear it run (we have !) but you'll have to be patient with my posting before I put the vid up.

As you can see we used a clutch alignment tool we had left over from doing the clutch on the old S13. So this was put to use on the Giken clutch. Amazingly the box literally just slid on, I hate putting boxes on and I was dreading doing this one with three plates to align.

Anyhow, all done, bolted up and nothing left to do but take a few pics of the now clean and spangly new looking yet empty engine bay :

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092172.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092174.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092175.jpg

Then we chained the engine up and began to ease it in one inch at a time :

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092176.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092177.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092178.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092179.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092181.jpg

Finally and after some faffing and jangling we got back on the new mounts exactly where we wanted it, notice the extended bottom cambelt cover due to the extra height of the 30 block :

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092182.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092183.jpg

Now for the best bit and the final dressing of the engine ready for mapping ! by this point only about 4 days away !

[Jeffers_S13]

So Dave wasnt happy with the first effort at doing the rear exhaust section and it looked a bit messy compared to Lance's (OJZ) manifold to say the least. So he ordered some more bends and bits from Jetex in Stratford :

http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091987.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091988.jpg

And then remade the whole rear section to slot neatly onto the centre section that Lance made for us :

http://i43.photobucket.com/albums/e356/Jeffers_S13/040420092039.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/150420092251.jpg

Few more pics wouldnt go amiss here so I'll leave space for when I get some.

[Jeffers_S13]

Just so you all know, Scott was always on hand to clean stuff and make things look pretty so me and Dave could crack on with other stuff. Here's some of his handy work on the drive shafts prior to fitment :

Before :

http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091986.jpg

After cleaning and some rubber treatment :

http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091985.jpg

Masked and painted :

http://i43.photobucket.com/albums/e356/Jeffers_S13/290320091998.jpg

Finished :

http://i43.photobucket.com/albums/e356/Jeffers_S13/290320091999.jpg

And the man himself cleaning stuff :D :

http://i43.photobucket.com/albums/e356/Jeffers_S13/100420092147.jpg

[Petrolhead]

i cant believe that is the same shaft :eek:

Does he want to pop round and do my subframe diff, shaft... pretty much the whole car:D

[Jeffers_S13]

We bought a driftworks wasted spark kit to go on the engine but after trying to find a suitable place to mount it we decided we didnt want to use it as we thought it was too much clutter in the bay once the HT leads were rigged up aswell. We have always intended to keep it as uncluttered as possible, plus it meant either leaving the plug cover off or drilling holes in it, neither of which we wanted to do. So after some searching Dave found these EVO packs that fit neatly under the plug cover.

http://i43.photobucket.com/albums/e356/Jeffers_S13/010420092016.jpg

We bought three and then I ended up with the challenge of having to mount them somehow. First of all the orientation of them was important and the general shape of them limited where stanchions could be put, First of all I was gonna make a singel tray for each one but it would have meant so odd routes for the paired HT leads to go.

So some wasted effort :

http://i43.photobucket.com/albums/e356/Jeffers_S13/280320091984.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/290320092003.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/290320092002.jpg

Then I ended up going for a single tray with holes in it for the HT leads (not shown in these pics).

http://i43.photobucket.com/albums/e356/Jeffers_S13/010420092017.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/010420092018.jpg

The 26 head has only a few places to mount the tray and I wanted to retain some stiffness so use a piece of ali angle with lots of odd cut outs to clear ribs in the head in the plug area. A few posts tacked on hold it at the correct height so the coilpacks sit neatly onto the plugs.

[Jeffers_S13]

i cant believe that is the same shaft :eek:

Does he want to pop round and do my subframe diff, shaft... pretty much the whole car:D

I know ! I can assure you it is ! he literally had blisters on his hands after he had spent nearly 4 days solid sanding, polishing and cleaning stuff :wack:

[SparkySX]

I have just read this from the first post to the last and OH MY GOD some effort has gone into this,
Its amazing!

Looking forward to more pictures!

[Jeffers_S13]

So whilst I started to dress the engine and do various other tasks Dave had begun to tackle the immense job of wiring the beast.

Start with one old loom :

http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092200.jpg

What a knotted mess, just used now for specific connectors for various OEM parts we are retaining.

Here's some pics of what £800 of wiring 'stuff' from Vehicle Wiring Products looks like :cry:

http://i43.photobucket.com/albums/e356/Jeffers_S13/080420092093.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080420092091.jpg

I've no idea how this small box of stuff was so expensive, but I went through the receipt a couple of times and it was deffo right.

We also bought a battery :

http://i43.photobucket.com/albums/e356/Jeffers_S13/140320091961.jpg

and a cool battery bracket to suit :

http://i43.photobucket.com/albums/e356/Jeffers_S13/060420092074.jpg

(which has since been anodised black with other parts)

And here is what is running it all :

http://i43.photobucket.com/albums/e356/Jeffers_S13/010420092022.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/010420092024.jpg

I made a sort of ladder frame to which the ECU, fuse/relay box and ballast resistors are bolted to, all hidden under the dash and the passenger footplate (yet to be made/fitted). Easy access and easy to remove.

http://i43.photobucket.com/albums/e356/Jeffers_S13/130420092218.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/130420092216.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/080420092089.jpg

And just a few of the early stages of the wiring process, got lots more just not uploaded them yet.

http://i43.photobucket.com/albums/e356/Jeffers_S13/110420092194.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092204.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092206.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092208.jpg

[Evilchap]

* PPS in Wiring Porn Shocker! :eek:

I have a feeling this is going to look the business when complete :D No details are being missed!

[Jeffers_S13]

http://i43.photobucket.com/albums/e356/Jeffers_S13/120420092209.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/130420092214.jpg
http://i43.photobucket.com/albums/e356/Jeffers_S13/130420092215.jpg

[Jeffers_S13]

* PPS in Wiring Porn Shocker! :eek:

I have a feeling this is going to look the business when complete :D No details are being missed!

Yes, Dave has done a frickin brilliant job so far. We have used only the best connectors and proper soldered and crimped terminals, all shrink wrapped ends, appropriate sleeving (heat proof, flexi, braided, or corrugated etc) p-clipped shrunk ends to keep tidy, soldered joints, correctly sized bulkhead grommets, micro fuses, micro relays etc etc. It will look as OEM as we can possibly achieve by the end of it, just as we wanted. Although we have also tried to 'tuck' the whole bay as much as possible so most of it will actually be hidden ! The loom has been made completely from scratch.

Loads more pics to come of this, it has been a mammoth task and has been pretty much all Dave has worked on for the last few weeks whilst I've done other stuff.

Obviously these pics were taken at the very early stages, its all MUCH neater now :smash: