My car's triumphant return: Another build thread
02-05-2016, 12:54 PM
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My car's triumphant return: Another build thread
Aside from specific questions, I'll be using this thread to document my 951's return to life. It's been down for a year with a blown motor, but it'll be coming back much stronger than before. It's a gutted street/AutoX *****.
Motor: Rebuilt 2.5 liter engine with stock rods and pistons, DIY AN-30 lap job, rebuilt head with 49mm intake valves and DIY porting. +4* advance cam key, stock intake manifold. 6 lb fidanza aluminum flywheel, HD sachs racing pressure plate, SPEC stage 2 clutch.
Turbo: HX35 inside a .63 T3 hotside, oil cooled.
exhaust: Custom 3" turboback with stock header and modified stock crossover. 40mm wastegate, vented to atmosphere
Turbo support: 24x11x3 FMIC, 2.5" piping, HKS SSQ BOV, 19 row 111 cubic inch oil cooler with -10AN hose.
Engine management: Microsquirt v3, self tuned. Running Speed/density algorithm, ls1 Coil near plug wasted spark ignition, GM 3 BAR MAP sensor, dual GM intake air temp sensors pre and post intercooler. Electronic boost control, integrated knock control, flex fuel capable.
Fuel system: Bosch 044 fuel pump, E85 rated fuel lines, 83# injectors, 3 BAR FPR, FPD delete.
Suspension/steering: 25.5mm front sway bar/18mm rear sway bar. Front coil overs on 300 lb springs, rear coil overs on 300 lb springs + 25.5mm torsion bars. Manual steering.
Other goodies: Custom rebuild transmission shift linkage, short throw shift lever, and heim joint transmission shifter link support. Sparco Sprint V seat and 5 point harness. Custom strut brace. Factory LSD.
NB 996 twists 18x7.5F/18x10R with 225/40/18 and 265/35/18 tires. Factory brakes for now. Car is gutted and weighs 2600 lbs.
Pics to come, still have lot of parts coming in the mail but I'm on track to have the car on the road in the next 6-8 weeks. Still a lot of work to do. My goal is 375 rwhp in a 2600 lb car.
It's good to be back
Motor: Rebuilt 2.5 liter engine with stock rods and pistons, DIY AN-30 lap job, rebuilt head with 49mm intake valves and DIY porting. +4* advance cam key, stock intake manifold. 6 lb fidanza aluminum flywheel, HD sachs racing pressure plate, SPEC stage 2 clutch.
Turbo: HX35 inside a .63 T3 hotside, oil cooled.
exhaust: Custom 3" turboback with stock header and modified stock crossover. 40mm wastegate, vented to atmosphere
Turbo support: 24x11x3 FMIC, 2.5" piping, HKS SSQ BOV, 19 row 111 cubic inch oil cooler with -10AN hose.
Engine management: Microsquirt v3, self tuned. Running Speed/density algorithm, ls1 Coil near plug wasted spark ignition, GM 3 BAR MAP sensor, dual GM intake air temp sensors pre and post intercooler. Electronic boost control, integrated knock control, flex fuel capable.
Fuel system: Bosch 044 fuel pump, E85 rated fuel lines, 83# injectors, 3 BAR FPR, FPD delete.
Suspension/steering: 25.5mm front sway bar/18mm rear sway bar. Front coil overs on 300 lb springs, rear coil overs on 300 lb springs + 25.5mm torsion bars. Manual steering.
Other goodies: Custom rebuild transmission shift linkage, short throw shift lever, and heim joint transmission shifter link support. Sparco Sprint V seat and 5 point harness. Custom strut brace. Factory LSD.
NB 996 twists 18x7.5F/18x10R with 225/40/18 and 265/35/18 tires. Factory brakes for now. Car is gutted and weighs 2600 lbs.
Pics to come, still have lot of parts coming in the mail but I'm on track to have the car on the road in the next 6-8 weeks. Still a lot of work to do. My goal is 375 rwhp in a 2600 lb car.
It's good to be back
Last edited by Dougs951S; 02-06-2016 at 12:16 PM.
02-07-2016, 09:59 PM
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Just ordered four 6006 2z C3 bearings (19 dollars shipped for all 4) and picked up some Allthread rod to make a bearing puller and rebuild my torque tube "while I'm in there".
I plan on using my impact gun to make the job relatively quick and simple. Also debating tearing my gear box down and replacing the synchros, or saving that job for another day since getting the gear box out is so easy. I really want to do it all at once and put it back together and have the car just be perfect, but that might be asking a little much. I can't really afford to rebuild the gearbox and the motor at the same time, along with all the upgrades I'm doing.
I plan on using my impact gun to make the job relatively quick and simple. Also debating tearing my gear box down and replacing the synchros, or saving that job for another day since getting the gear box out is so easy. I really want to do it all at once and put it back together and have the car just be perfect, but that might be asking a little much. I can't really afford to rebuild the gearbox and the motor at the same time, along with all the upgrades I'm doing.
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09-10-2016, 10:43 PM
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Thought I'd update this. The car is by my estimation 6-8 weeks from being back on the road!
The motor is a refreshed 86 engine with 50k miles on the clock. The engine is getting:
All seals replaced
front seal races
oil pump drive gear
belts and all belt rollers
water pump
rod bearings
+4* advance cam key
rebuilt head
The car is also getting a rebuilt torque tube, so that's nice.
Much progress has been made on all the previously mentioned goodies. Just wanted to let everyone know this build wasn't forgotten. It's been moving along behind the scenes and I will have lots of pictures and a few secrets to reveal soon enough. Currently building a new custom harness for the megasquirt that will be greatly superior to my last setup. Stay tuned.
The motor is a refreshed 86 engine with 50k miles on the clock. The engine is getting:
All seals replaced
front seal races
oil pump drive gear
belts and all belt rollers
water pump
rod bearings
+4* advance cam key
rebuilt head
The car is also getting a rebuilt torque tube, so that's nice.
Much progress has been made on all the previously mentioned goodies. Just wanted to let everyone know this build wasn't forgotten. It's been moving along behind the scenes and I will have lots of pictures and a few secrets to reveal soon enough. Currently building a new custom harness for the megasquirt that will be greatly superior to my last setup. Stay tuned.
10-08-2016, 11:07 PM
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Update: Motor is 100% assembled and due to be dropped into the car tomorrow. I decided to continue running the k27/8 for simplicity sake just for the time being. I decided to rebuild it myself while it was out of the car. After new piston rings and seals and a professional rebalance, it's good to go and definitely much tighter!
I decided not to rebuild the torque tube, I would like to get this car driving again and I'm nearly at the reassembly stage. It's something that needs done, but I think it can wait till I have more space to do it in a year or two.
The head was refreshed, but I decided to go with stock valves because my machinist expressed doubt about being able to fit the 49mm intake valves without extensive machine work. The cam advance key I ended up using appears to be a 2* advance unit. Again, easy to change out later if I so desire.
The new wiring harness is basically complete, and in general between the cleaning and tidying and all the fresh paint; the engine bay looks 1000x cleaner than before.
What remains after getting the motor in is reinstalling the transaxle, wiring everything up, reinstalling the radiator and fans, and hooking the shifter and exhaust back up.
I have designed the layout for the IC pipes and the oil cooler lines, and am currently working on fabbing the pipes and stainless lines and getting the FMIC and oil cooler installed. That's pretty much it.
School is taking up most of my time, but I should be up and running soon!
I decided not to rebuild the torque tube, I would like to get this car driving again and I'm nearly at the reassembly stage. It's something that needs done, but I think it can wait till I have more space to do it in a year or two.
The head was refreshed, but I decided to go with stock valves because my machinist expressed doubt about being able to fit the 49mm intake valves without extensive machine work. The cam advance key I ended up using appears to be a 2* advance unit. Again, easy to change out later if I so desire.
The new wiring harness is basically complete, and in general between the cleaning and tidying and all the fresh paint; the engine bay looks 1000x cleaner than before.
What remains after getting the motor in is reinstalling the transaxle, wiring everything up, reinstalling the radiator and fans, and hooking the shifter and exhaust back up.
I have designed the layout for the IC pipes and the oil cooler lines, and am currently working on fabbing the pipes and stainless lines and getting the FMIC and oil cooler installed. That's pretty much it.
School is taking up most of my time, but I should be up and running soon!
10-09-2016, 01:14 AM
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They'll come. Sadly, I dropped and broke my phone a few days ago working on the motor incidentally. The glass is intact, but it broke the AMOLED panel 
It was cheaper for me to buy a used S5 active than it was to repair my old S4 so that's what I did. I ordered one off ebay in great shape for 130 bucks, I'm supposed to be getting it next week.
It was cheaper for me to buy a used S5 active than it was to repair my old S4 so that's what I did. I ordered one off ebay in great shape for 130 bucks, I'm supposed to be getting it next week.
10-09-2016, 11:59 AM
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Gates barricade hose. More info about my fuel lines can be found here.
https://rennlist.com/forums/944-turb...-fittings.html
https://rennlist.com/forums/944-turb...-fittings.html
10-09-2016, 08:37 PM
#15
Gates barricade hose. More info about my fuel lines can be found here.
https://rennlist.com/forums/944-turb...-fittings.html
https://rennlist.com/forums/944-turb...-fittings.html