Shadowman's S13 blacktop hatch build thread

[ShadowMan]

I've had this car for a few years already. But as you'll see it's still in rough shape. Due to my deployments and obligations to all that, this hog gets pushed to the back burner often. Due to leaving it in the hands of not so knowledgable friends who fiddled with the Power fc settings, cylinder number 4 detonated and destroyed the ring lands. So I broke down and decided to try my hand at rebuilding the motor myself, armed with an FSM and the tools I've acquired over the years, I gave it my best shot. So here goes, didn't take alot of pics, when I get on point I just zone in to the task at hand
how she sat before the rebuild
http://img843.imageshack.us/img843/465/47074252.jpg
http://img98.imageshack.us/img98/6606/95989354.jpg
the tear down
http://img99.imageshack.us/img99/4594/12084490.jpg
http://img534.imageshack.us/img534/5394/66613401.jpg
http://img191.imageshack.us/img191/1194/22668383.jpg
addressing the harnes while rebuild kit from frsport is on order
http://img43.imageshack.us/img43/8436/25563844.jpg
http://img406.imageshack.us/img406/2868/93855245.jpg
http://img542.imageshack.us/img542/9933/26467992.jpg
As I didn't know the cause of why she was burning oil, this was my first clue to the problem
http://img809.imageshack.us/img809/6966/90797503.jpg
son of a bitch, knew this coming
http://img215.imageshack.us/img215/8550/67020283.jpg
tear down continues
http://img853.imageshack.us/img853/3871/28892614.jpg
http://img201.imageshack.us/img201/7913/49946329.jpg
http://img69.imageshack.us/img69/3394/21977676.jpg
not good
http://img823.imageshack.us/img823/1888/40355680.jpg
Pretty happy about how clean this all was after removing the valve cover
http://img404.imageshack.us/img404/6329/54164234.jpg
http://img688.imageshack.us/img688/9467/10115627.jpg
And finally the problem rears its ugly head, this is why driving on a shitty tune is bad
http://img259.imageshack.us/img259/6425/38188200.jpg
pulled it out and little ring land pieces went everywhere
http://img705.imageshack.us/img705/2282/77563005.jpg
http://img692.imageshack.us/img692/134/24844451.jpg
http://img69.imageshack.us/img69/2892/58251073.jpg
All the pictures of putting it back together got erased so bummer on that. I reused the rods, went with oem pistons and rings, arp hardware, acl bearings, supertech valve seals, new timing kit, new oil pump, apex hg, new rear main seal. I ran into the same problem with a couple of the main studs hitting the oil pan. I initially shaved the oil pan little by little until i thought i had the clearance but ended up cracking it anyway. So I had the pan welded and shaved the excess off the studs. Suggest just trimming the main studs from the get go, as have many others. Got everything back together and reinstalled. Ordered a base map from Steve Shadows, and broke her in nice and easy with conventional oil. Changed after initial startup and 5 min run, 50 miles, 100 miles, 500 miles, 1000 miles and now on regular intervals. Drove it up to canyon racer motorsports for a dyno tune. The motor came with after market injectors and Steve and I could not figure out their size. I havent have them flow tested either. So we played it safe and stopped at around 200 whp until I get my fuel system sorted out. I plan on going with a top feed setup soon so hopefully my fuel setup will be completed soon. I still need to go thru all my sensors to make sure they are getting the right voltage as she still has an irregular idle and wants to sputter when trying to cruise at any steady speed. Acceleration is strong but not quite consistent, so hopefully I'll have all that sorted out. I just need to pick up a reliable multi-meter, and a wideband O2 as well.
S13 blacktop
z32 maf
3" exhaust straight piped
turbonetics t3t4 60 trim
38 mm tial wastegate
open dump pipe
greddy turbo timer and boost controller
Apex power fc
aeromotive fpr with marshall gauge
Battery relocated to trunk
I hope to stay on this steady as I'm done deploying, so hopefully the updates will be steady as well.

[Kk_kalina]

pics are way to small

[ShadowMan]

I had a knock of nismo fpr and wasn't too sure about the reliability of it so I went ahead wand threw the aeromotive unit on with a tomei fuel rail adapter, along with a marshall fuel guage and black -AN fittings to tie the return lines all together.
Also had to jerry rig a mounting assembly for the fpr, just some aluminum anlge and flat stock from Lowes, made it larger than neccsary in case anything else needs to get mounted nearby.
http://img137.imageshack.us/img137/9229/p4230459.jpg
http://img545.imageshack.us/img545/9721/p4230460.jpg
http://img269.imageshack.us/img269/3474/p4230461.jpg
http://img534.imageshack.us/img534/6935/p4230462.jpg
Redid the intake filter and pipe as well
http://img404.imageshack.us/img404/6233/p4230463s.jpg
And some pics of the battery relocation install I did
http://img31.imageshack.us/img31/7726/p4230464.jpg
http://img694.imageshack.us/img694/267/p4230465.jpg
The interior with the greddy turbo timer and boost controller, boost gauge, oil pressure and tem gauge and the power fc. I plan on relocating the gauges to a more practical location when I get around to it.
http://img821.imageshack.us/img821/2165/p4230466.jpg
And the screamer/dump pipe, when I finally tackle the exhaust I plan on plumbing it back into the exhaust. Its been fun deafening people for a while but I've had my fill with it.
http://img857.imageshack.us/img857/9909/p4230467.jpg
Slowly but surely. Hopefully I can get a wiring specialties harness and wideband O2 soon to help eliminate some gremlins and keep a better eye on whats going on under the hood.

[ShadowMan]

added this dc strut bar, I like this look alot better and its a solid piece , no swivel bolts so its alot sturdier
http://img844.imageshack.us/img844/8895/p5200466k.jpg
http://img685.imageshack.us/img685/5192/p5200465.jpg
Got this hatch spoiler but it wasnt quite what I wanted so a little fiberglass, body filler and paint. Still not exactly what I like but it's closer than the little wedge that showed up.
this is how it originally looked
http://img848.imageshack.us/img848/4775/p5120460.jpg
http://img205.imageshack.us/img205/8315/p5120459.jpg
http://img843.imageshack.us/img843/7517/p5120461.jpg
and this is after my amatuer fiberglass job
http://img822.imageshack.us/img822/9098/p5200472.jpg
http://img515.imageshack.us/img515/5303/p5200471.jpg
http://img841.imageshack.us/img841/8159/p5200470.jpg
New/used parts showing up at the rapid so more to come. Hopefully I'll finally be able to get my power steering assembly finally pieced together and be able to enjoy one hande steering.

[S-Nation S13]

your in oceanside, im surprised i dont see you cruising around lol..probably bc your cars been out of commission..keep it up seem like you having fun with the whole build thing..

[lewisfk]

Hey man did i stop by your house a month ago? Black dude in blue Ford Ecoboost? If so did u find that extra zmaf sensor?

[S13x88]

Hey man did i stop by your house a month ago? Black dude in blue Ford Ecoboost? If so did u find that extra zmaf sensor?

I don't think you have the right guy.....

http://img215.imageshack.us/img215/8550/67020283.jpg

[ShadowMan]

Hey man did i stop by your house a month ago? Black dude in blue Ford Ecoboost? If so did u find that extra zmaf sensor?

Yeah definitely not me. And S-Nation s13 Ive been out and about a little, mostly running errands. I dont really know where everybody likes to go cruise either. Ive been to the thursday night meet off the 76 and college once. After Im finished with this marksmenship trainer course I'll be out a bit more hopefully.

[lewisfk]

Well there is a guy living in base housing with a similar car! If your selling parts let me know im local!

[ShadowMan]

new parts, well new to me anyway. In montana picking up my gtir motor I left behind, which is for sale btw. Be back to cali sunday, and hopefully have the energy to put some of these on, but after 22 hours of driving we'll see.

Newish clean valve cover with the lines and fittings
http://img526.imageshack.us/img526/4072/p5240466.jpg

isis intake mani, not a polished type of guy so I'm going to give wrinkle black a try. Not exactly sure how to prep this mani for something like that, yet.
http://img6.imageshack.us/img6/8048/p5240467.jpg

Oil catch can for the hose that runs from the VC to the intake before the turbo. Just curious if this is worth it or not. Got it all for a deal so I figured couldn't hurt to throw it on and see, right?
http://img403.imageshack.us/img403/5182/p5240468.jpg

And the missing link to my power steering system, well at least I think. as far as the other lines go, its my understanding the other lines are just a descent rate rubber hose, but I'll have to look into my fsm to be certain.
http://img163.imageshack.us/img163/7729/p5240469.jpg

[ShadowMan]

Well there is a guy living in base housing with a similar car! If your selling parts let me know im local!

Did you hit me up at the px a bit ago, in the stuart mesa housing?
I am selling parts, I do have an extra z-maf but I'm hanging onto it for now until my next dyno run to make sure everyting I have is working good. I live in the stuart mesa area, so if you want to stop by and see what I have, by all means do. I would love to sell off the rest of my stuff so I can get other stuff for my car and stuff, nothing in particular, just......stuff.

[ShadowMan]

Alright, got some of this stuff figured out temparaily. Just need to figure out final mounting points and hose lengths. I'm going to try to take these blue and red -AN fittings over to vw heaven to trade em for some black ones since they carry alot of it in stock usually. I guess this a functioning mock up for my DD. I obviously need additional AN fittings to get rid of the black hose running from the greddy catch can to the intake pipe. I decide to do all this today as well as retorque the head studs, which were still at holding at 80 lbs. so it ended up just being for my peace of mind. Replaced to old vacuum hoses as well that run by the fuel lines. Once I get my isis intake mani prepped, this valve cover is coming off again and I think I'll go wrinkle red or black for the VC and probably wrinkle black on the intake mani but not sure yet.
Now for the pics
http://img594.imageshack.us/img594/1402/p6080482.jpg
http://img38.imageshack.us/img38/9229/p6080480.jpg
this big black hose is gay as shit, but it'll be gone soon enough as well as relocate the nipple on the side closer to the greddy unit.
http://img210.imageshack.us/img210/6070/p6080479.jpg
http://img801.imageshack.us/img801/5761/p6080478.jpg
Hit up one of the 240 meets last night off the 76 and college and got some insightful info from some local 240 guys and some ladies as well. Hopefully my power steering system will be finally pieced together tomorrow and up and running by Sunday. Got a father/son fishing trip in Dana Point tomorrow afternoon with my boy so it will most likely be sunday. Just need to source out a new fuel rail and injectors so I can get off this break-in tune and get some real power.

[PG BOOSTED]

Nice build dude

[ShadowMan]

Two other things that I am really excited about but most will probably think is stupid. Notice the pink fuse box cover on the passenger side engine bay box? Well Im just happy to have one now, wish it were white but whatever, itll keep the crud out for now, and now I can open my trunk using the key. Stupid right? I dont care though Im happy now. Thanks Vatche for the fuse box cover, refusing to let me leave the Denny's parking lot with out a working hatch lock and getting me the power steering parts I need.

PG BOOSTED- thanks for the compliment, hopefully I can start on cleaning it up a bit too.

[ShadowMan]

dual electric fans finally. Still figuring out some of my wiring so right now they are each wired into seperate toggle switches. Once I get my new WS harness I'll wire them into relays and a thermostatic switch or whatever they're called.
http://img137.imageshack.us/img137/7175/p6100493.jpg
http://img201.imageshack.us/img201/3728/p6100494.jpg
http://img217.imageshack.us/img217/989/p6120495.jpg
http://img32.imageshack.us/img32/2691/p6120496.jpg

[ShadowMan]

Since I'm not big on chrome, I've been working on getting the intake manifold prepped. Since it is an ISIS unit, it has all the crappy casting "extras". So Ive just been using my files and harbor freight ghetto dremel to get all the chrome off and smooth out all the bumps and low spots.
http://img98.imageshack.us/img98/1058/p7020069.jpg
http://img94.imageshack.us/img94/6826/p7080087h.jpg
http://img842.imageshack.us/img842/2622/p7080088.jpg
http://img688.imageshack.us/img688/3923/p7080089.jpg
http://img856.imageshack.us/img856/4905/p7080090.jpg
http://img545.imageshack.us/img545/5446/p7150084.jpg
Also got in the new WS harness. Aside from soldering on the new injector clips, I'm leaving all the clips on it so when I decide to resell it, more people will be able to use it.
http://img713.imageshack.us/img713/2787/p7060083l.jpg
http://img23.imageshack.us/img23/838/p7060084.jpg
http://img6.imageshack.us/img6/3793/p7060085.jpg
http://img137.imageshack.us/img137/3924/p7060086.jpg
Also, my exhaust had been rubbing on my bumper, so I tried my hand at cutting the hangers and rewelding em to get it away from the side. They are crappy welds but they work.
http://img864.imageshack.us/img864/9322/p6220056.jpg
http://img838.imageshack.us/img838/8193/p6220057.jpg
http://img716.imageshack.us/img716/9930/p6220059n.jpg
http://img715.imageshack.us/img715/9052/p6220060.jpg
http://img401.imageshack.us/img401/7024/p6220061x.jpg
http://img805.imageshack.us/img805/6963/p6220062.jpg
http://img232.imageshack.us/img232/3938/p7160085.jpg
got it moved just enough for it to quit banging against the bumper when it idles like shit. But I also ordered a new coolant temp sensor for the ecu so hopefully that solves the crappy idle.

[PG BOOSTED]

its coming along for you dude just keep at it. You should powdercoat the intake manifold gold like your current rim color. thats just my personal opinion

[kennedy8383]

I like how the battery setup at the back..

[ShadowMan]

its coming along for you dude just keep at it. You should powdercoat the intake manifold gold like your current rim color. thats just my personal opinion

Not sure if I'll be sticking with this color for the wheels but I will think about your suggestion once I pick a wheel color. I'm also just considering a wrinkle black for the VC and intake mani. But who knows...

[ShadowMan]

I like how the battery setup at the back..

Thanks, I've had this kit for a while. It was in my G20 first and now this. Aside from having to pull the lid off when I want to dissconnect the battery, I have no complaints about it.

[ShadowMan]

Just had my second son a week ago and everything leading up to him has kept me pretty busy getting everything ready for his arrival. But I have made a little progress. Almost got the intake all filed down and did some test fitting. Looks like the holes all line up with the stock fuel rail, just need to get some new injector bushings. I also ordered the cold pipe to get it mounted up so that should be here by middle of next week. I also ordered the FC datalogit and the Innovate MTX-L wideband which should also be here next week some time. Here are just a few pics of test fitment of the fuel rail to the IM.
http://img545.imageshack.us/img545/5446/p7150084.jpg
http://img72.imageshack.us/img72/9528/p7270087.jpg
http://img822.imageshack.us/img822/4120/p7270088.jpg
http://img228.imageshack.us/img228/8232/p7270098.jpg
I have pretty much hand filed the majority of the IM and used my ghetto harbor frieght die grinder to get the nooks and crannies where the files wouldn't reach. I have also filed and grinded a bit of the casting leftovers/marks or whatever they're called down a little bit. Here's where I would like some opinions. I have the circuit sports thermal barrier gasket for the IM and when I placed it on the manifold, the ports don't match the gasket. I'll get a pic up tomorrow to show what I'm talking about, but for those of you that know what I'm talking about should I port match the FREDDY manifold runners to the gasket or leave it be. I'm definitely not porting the head on my own so just looking for a little feedback. Thanks for looking.

[ShadowMan]

The Innovate Wideband showed up. Came packaged nice and bubble padded. So here it is. I know there are probably alot of others out there that would like to see a write and review on this so I will give it a try. This is the MTX-L unit and all it came with.
http://img823.imageshack.us/img823/8764/p8110166.jpg
Hopefully by next weekend I can have this installed.

[pablo13]

Coming on well :)

[ShadowMan]

So I got the wideband installed and took pics. Went rather smoothly since there was already a bung on the exhaust and I already had a spot for the gauge. Overall, I'm happy with it. But I'll just get right inot it.
First things first, find a switched 12v source
http://img195.imageshack.us/img195/7779/p8130169.jpg

Find a headlight power wire, I already have gauges over here so I tied into the wire supplying them.
http://img9.imageshack.us/img9/8435/p8130174.jpg

Once I located the neccesary wires, I disconnected the battery
http://img11.imageshack.us/img11/3796/p8130167.jpg

This is the oil temp gauge I no longer need, so the Innovate gauge will take its place.
http://img444.imageshack.us/img444/3832/p8130168.jpg

MTX-L installed
http://img835.imageshack.us/img835/5936/p8130197.jpg

Red wire on MTX-L goes to switched 12v, which is this green wire supplying 12v for my other 2 gauges
http://img402.imageshack.us/img402/6889/p8130172e.jpg

Again, white wire on MTX-L goes to headlight wire, which is this thicker white wire supplying switched power for the other gauges lights. This wire works differently for the MTX-L . It dims the display when lights are turned on so it's not too distracting at night. If you don't want the display on the gauge to dim when it's dark and you turn your lights on, then ground this wire to the chassis.
http://img9.imageshack.us/img9/8435/p8130174.jpg

Black wire on MTX-L is the ground wire. Keep it away from radio grounds or anything similar that has a lot of "electrical noise". As per the instructions, it could interfere with MTX-L unit, similar to the reason MAF wiring is shielded.
http://img341.imageshack.us/img341/1245/p8130173.jpg

The yellow and brown wire are analog outputs for either your ecu or datalogging, I will be using these later but for now not neccesary. So I individually heat shrinked them, then heat shrinked them together.
http://img88.imageshack.us/img88/2986/p8130171.jpg

So here's the wires behind the glove box area. I'm not worried about how the wires look now as I have a few more things to do under here, so it will get cleaned up in later this week.
http://img443.imageshack.us/img443/6654/p8130175.jpg

Before you hook up the actual sensor to the MTX-L, the unit needs to calibrate itself. So now that everything is wired up, hook the battery up and switch the car to accessory or on position. The gauge will cycle on lighting up the entire digital readout and sweep the light bar across the enitre spectrum. The it will show E2, which is error code for no sensor, which is great because the O2 sensor not plugged in yet.
http://img42.imageshack.us/img42/2744/p8130178.jpg

Then the car gets turned to the off postion or just remove the keys, the O2 sensor gets plugged in and is allowed to sit in the open for a "free air" calibration. So I plugged it in and set it on the box to keep it off the ground.
http://img831.imageshack.us/img831/9851/p8130179.jpg

Turn key to the "on" position, no need to start the car. The gauge will show "Htr". This is the sensor heating up so it can get accurate readings. I took these 2 pics because as the method the gauge uses to display the reading, the camera catches it in between it pulsing the readout, weird. It only looks like this in a pic. It shows a constant display to the human eye.
http://img685.imageshack.us/img685/6759/p8130181d.jpg
http://img208.imageshack.us/img208/5170/p8130182s.jpg

After 30-60 seconds it will display the reading which will be 22.4 because that's the gauges upper reading limit of lean and since the gauge is sitting in open air that's correct.Now power the car off again and it's time to mount the sensor. You can unplug the sensor and you won't have to recalibrate it as long as you do not power the car on while it is unplugged.
Time to make a hole
http://img10.imageshack.us/img10/5042/p8130186.jpg

After about 5 minutes it finally punches through. Here you can see the bung that was already in the exhaust for me as well. Score!
http://img12.imageshack.us/img12/4614/p8130188.jpg

Painted the hole and applied some gasket maker.
http://img689.imageshack.us/img689/6164/p8130189.jpg

Then a rubber gromet and more rtv.
http://img525.imageshack.us/img525/7720/p8130191.jpg

Found this old broken scope cap that I filed a slot in, then used another grommet to help keep the water and debree out.
http://img171.imageshack.us/img171/2938/p8130192.jpg

Slit the small grommet, slipped the wiring into that, generously applied more rtv and placed the whole ensemble in place.
http://img32.imageshack.us/img32/5471/p8130195.jpg

Then sprayed it all black.
http://img849.imageshack.us/img849/1763/p8130196.jpg

Everything went relatively smoothly especially having the bung already in the exhaust. Had an old broken O2 to keep it plugged. Old on the left, New on the right.
http://img171.imageshack.us/img171/1880/p8130185.jpg

If anyone has any questions on it feel free to ask. I'd also like to point out that I got the MTX-L with the 8ft sensor cable option. Needless to say i have about 4 ft coiled up under the dash but when I use it for dyno tuning it will come in handy having the extra cable. They offer it in a 4 ft cable which would be fine, should be able to mount he gauge any where on the dash with the 4 ft option. Thanks for reading.

[ShadowMan]

Finally getting around to getting the new intake manifold mounted up. Still need a iacv hose and also need to modifly the cold side piping, but it should be done by thursday afternoon sometime. Anyway, on with the pics.

Getting the old one unhooked and out
http://img407.imageshack.us/img407/4527/p8150206.jpg
http://img259.imageshack.us/img259/5882/p8150207.jpg

New one prepped and ready to go in
http://img594.imageshack.us/img594/8140/p8150208.jpg
http://img15.imageshack.us/img15/8017/p8150209.jpg

Somewhat settled in
http://img405.imageshack.us/img405/6959/p8150211.jpg

Slight mod to the fuel rail, out with uneccesary hardline and just an extended fuel line
http://img138.imageshack.us/img138/2268/p8150212.jpg

Once I get it finished tomorrow I'll get the finished pics up.

[ShadowMan]

Got her all finished up. Just had to run out and grab some 3/4" ID hose for the IACV and cut up my new isis cold pipe to get it to match up to my other IC piping. All in all, I'd say this went pretty smoothly. Spent about 4 hours actually working to get it done. Thankfully I'm a hoarder and never throw/give anything away. I hade all the vacuum line fittings to screw into the ports under the throttle body and on the underside of the IM so now everything has its one vacuum/boost source, no tee's. My next purchases are a new topfeed fuel rail and some ID 1000's, so pay no attention to that fuel line running across the top of the manifold. When I purchased this badboy it already had the converted throttle body or maybe the whole thing is an s14 unit, I don't know. Either way all I had to do was flip my throttle cable bracket 180 and it works just fine.
fuel rail and lines fitted
http://img23.imageshack.us/img23/4617/p8160205h.jpg
All finished up
http://img195.imageshack.us/img195/6163/p8160206.jpg
http://img163.imageshack.us/img163/4961/p8160207.jpg
Any comments and critiques are welcome. Thanks for looking.

[KiLLeR2001]

Sweet build, very similar to my car! I see that the car was originally red. Are you planning on keeping it black or going a different color?

[ShadowMan]

I actually have been thinking of a different color but non in particular. Something that won't show the dirt as fast. Even after I'm done washing it, 5 minutes later it looks dirty. Maybe like a gunmetal grey or something.

[ShadowMan]

My FC Datalogit finally arrived so I'll be spending time getting familar with the software to get it to datalog with the wide band and get my map refined. Looking forward to learning this aspect of the build. Also, I have yet to see any oil collecting in the the catch can with my current setup, in case if anyone was wondering about trying this setup out.

[ShadowMan]

Well now that my new kid is a little more self sufficient and can entertain himself, I've been able to abuse my poor car some more. Decided that the placement of the intercooler was horrible, giving it more than its fair share of abuse, so I figured why not put it right where the old AC condensor used to be. While I was removing everything and test fitting the new spot I figured I might as well replace the front core support seeing how the previous owner's shop, did a half assed job of measuring and welding it in place for the s15 front end. While I was doing that, I knew I needed to get the wiring out of the way so that while I was welding new stuff, the harness wouldn't get fried. Thee-eeeeennn I figured since I had the front part of the chassis harnes pretty much out of the car already, I might as well do a wire tuck. So now, here I sit, with a plan that resembles a 2 yr olds finger painting, that originally started out with a simple intercooler relocation, that hasn't been done, that mutated into a semi tube front/bash bar fab, that has now transmorphorized into a mess which has led to the removal of the entire interior to get this wire tuck finished. Sometimes I really wish I had a different hobby, but I'm a glutton for punishment I guess. Anyway, here's the progress. Sorry for not taking more pics.

I separated the fuse boxes in half so I could snake them through the original holes w/o cutting new ones.
http://imageshack.us/a/img7/668/pb150463.jpg
http://imageshack.us/a/img547/4900/pb150464.jpg

Couple pics of the interior gutted and the wiring taking control.
http://imageshack.us/a/img94/2631/pb160466.jpg
http://imageshack.us/a/img255/9723/pb160467.jpg

I bought some tubing and gathered some scrap for practicing and the new front end. But more of that later.
I'll try to get more pics tomorrow.

[ShadowMan]

So I got some goodies recently. My fusebox relocation is at the point where I can leave it alone and get back to why I first started this current project, mildly tubing the front and building a crash bar. If anyone wants to chime in with some advice I'm all eyeballs. I'm thinking that I can re-use my current intercooler and mid mount it to keep it protected as well as cut down on the number of piping couplers I'll need. From searching around, I'll just make sure my ducting is as effecient as I can.
So I borrowed this welder
http://imageshack.us/a/img28/5348/pc080002x.jpg
And scored this 55 gal drum for free to make the tubs. It used to hold methenol but it's been airing out for a week or so now, but I'll purge it with some of the gas from the welder just so I don't Wyle E. Coyote myself.
http://imageshack.us/a/img832/2430/pc080004.jpg
And picked a 20' stick of 1.5" .120 tube and 1" .95 tube with some other scrap sheets and misc. square tubing.
http://imageshack.us/a/img690/1348/pc080005w.jpg
I've been googling the shit out of s13 front ends as well as scouring the fabrication thread and members build threads, so I have a few ideas but nothing set in stone. So many high quality projects and ideas. Hopefully my method of attacking things with wreckless abandonment and persistance pays off. hahaha

[ShadowMan]

I'm on my second page, awesome-ooooooooo

[ShadowMan]

I forgot that welding is 75% prep work 15% welding and 10% wondering if you should take it apart and start over. So after staring at the front end for a few days, and measuring and staring again I decided to finally just cut into it. Whoever put the s15 front end on should just stop touching cars, no pride or skill was involved in the making of this gobbly-gook that the previous owner took it to. It worked but thet cut alot of corners. Not exactly sure how much to keep and how much to cut away for the tubs, so I'm still figuring out the best way to go about those.
http://imageshack.us/a/img545/3433/pc210001i.jpg
Here's some of the garbage boogers someone tried to disguise as welds
http://imageshack.us/a/img41/9917/pc210002.jpg
Lower cross member out. I just hit the spot welds with my angle grinder and a couple hits with a hammer to motivate it out.
http://imageshack.us/a/img818/7776/pc210004t.jpg
Im want to try and reuse this but it definitely is not a flush fit so Im not sure yet.
http://imageshack.us/a/img824/2897/pc210009.jpg
Got the frame rails cleaned up. Lots of unneccesary holes and tack welds, booooo.
http://imageshack.us/a/img59/4048/pc210010d.jpg
http://imageshack.us/a/img818/6619/pc210011.jpg
http://imageshack.us/a/img687/1948/pc220012f.jpg
And here's the drum again I plan on using for the tubs. Now this is where you the reader get to chime in because I'm curious if I should incorporate the grooves from the drum into the tub for added strength or if someone tried this and it back fired and looked horrible.
http://imageshack.us/a/img10/5809/pc210005q.jpg
After these next couple days I'll be able go at it again. And like I said, I'm all ears for any advice for any body that actually reads this thread.

[ShadowMan]

Made a little more progress but not much. This would be so much easier with the proper tools but I can make do with what I have. Tried my hand at a little stitch welding, some are ok others, not so much. I'm sure the function is there even if the form is a bit, well, ugly. I also got the driver side wheel well cut out and am in the process of making templates. Too bad I'm not really all that good or I would try to make it look like a pro. Anyways, on with the pictures.
A couple shots of some amateur stitch welds. I did this before I cut stuff out hoping it would help beef things up a bit.
http://imageshack.us/a/img832/166/pc270015.jpg
http://imageshack.us/a/img15/4231/pc270016.jpg
Nothing new, just a cut out wheel well. I'll be removing more material as I get pieces tacked in and fitted, but I'm a little bitch so I'm going a little at a time. I'll get the driver side finished first, that way I won't be so paranoid when I get to the passnger tub and will have a better idea of what to cut.
http://imageshack.us/a/img201/157/pc270017q.jpg
And the beginnings of the templates.
http://imageshack.us/a/img339/7005/pc270018.jpg
Hopefully, I'll have both tubs at least mocked up by tonight. I'm also going to start on my tube front as well. My buddy had to take his welder back for a few days, but my neighbor has a gasless mig that I can borrow to at least tack weld most of it together. We'll see how it all goes though. I also need to go pick up some of that POR15 shit or whatever its called as well as some seam sealer, weld thru primer and paint. Alright, back to work I go.

[ShadowMan]

This is as far as I managed to get. Got both tubs cut out and trimmed them to fit around the strut towers. I'm still trying to come up with the best/cleanest/strongest solution for the side pieces. I'm pretty sure I stand there staring at it more than anything else.
The tubs being cut from the drum, which takes a long time with a cutoff wheel.
http://imageshack.us/a/img829/1128/pc270014n.jpg
http://imageshack.us/a/img402/166/pc270015.jpg
Trimmed to fit
http://imageshack.us/a/img545/4231/pc270016.jpg
Drivers side ready to weld, passenger side is just sitting there waiting to be fitted into place.
http://imageshack.us/a/img546/5374/pc270017.jpg
Here's where I have a couple questions. How far down from the top of the strut tower should the tub be welded?
http://imageshack.us/a/img221/7005/pc270018.jpg
And how far forward is everyone bringing their tubs?
http://imageshack.us/a/img267/655/pc270019.jpg
I just went with what looked as close to what everyone else is doing so unless someone chimes in with some answers, I'll just keep on keepin on. I'll have more tomorrow.

[AWahl]

lol at those garbage boogers

[ShadowMan]

The more I work on this hog the more respect I have for those of you that make this shit look good. This would definitely be going faster if I had the right tools but I don't, so slow it goes. Got a liitle bit closer on the driver side tub. Anyways, on with the pictures.
http://imageshack.us/a/img802/7528/pc280014.jpg
http://imageshack.us/a/img23/4382/pc280015a.jpg
http://imageshack.us/a/img4/2589/pc280017.jpg
http://imageshack.us/a/img521/8845/pc280018g.jpg
http://imageshack.us/a/img197/9990/pc280019.jpg
http://imageshack.us/a/img141/4098/pc280020m.jpg
http://imageshack.us/a/img819/7484/pc280021.jpg
http://imageshack.us/a/img14/7612/pc280022.jpg
It's just tacked in place as of now. Hopefully I'll have both sides finished by tomorrow, but we will see.

[ShadowMan]

Not much progress, but here it is.
http://imageshack.us/a/img19/5814/pc310015.jpg
http://imageshack.us/a/img845/4747/pc310016.jpg
http://imageshack.us/a/img59/5632/pc310017k.jpg
http://imageshack.us/a/img40/5876/pc310018.jpg
http://imageshack.us/a/img141/2593/pc310019y.jpg
http://imageshack.us/a/img138/9375/pc310020u.jpg
http://imageshack.us/a/img706/6934/pc310021u.jpg

[ShadowMan]

I know most of you people are probably shaking your heads at my build, which is great, because I am too. So we can laugh some more at what else I've done. I tore all the front support shit, that I was doing, out because it gave me a head ache looking at it. Then I did this which I think is a better idea.
http://imageshack.us/a/img17/3333/p1060016u.jpg
http://imageshack.us/a/img818/5593/p1060017d.jpg
http://imageshack.us/a/img690/7937/p1060018b.jpg
http://imageshack.us/a/img62/8306/p1060019f.jpg
http://imageshack.us/a/img16/4300/p1060020s.jpg
http://imageshack.us/a/img197/5043/p1060021kp.jpg
I'm working on getting a pipe bender, but for now it's angle cuts and welding. I plan on making the center bars, wether I keep this or change it a little bit more, removable for ease of engine install/removal. Learned a lot so far, but unfortunately its mostly from doing it wrong first, so more time has been spent undoing mistakes rather than making progress. Besides that, I think I have found a completely original powerplant. I don't think I have ever seen anyone use it before either. I've been researching it closely for about 5 1/2 months now, and it seems to have an unknown power potential. So far, all studies and close observations have seen it tested for hours on end, during all kinds of conditions with zero fatigue of any parts. Actually the longer it runs, the power the source seems to actually produce. Obviously, custom fabrication will be needed to seat the power plant in the engine bay, but it should be minimal. Would you like to see it? Well here it is
http://imageshack.us/a/img204/2518/p1020015t.jpg
Like I said, unlimited power levels that make the energizer bunny look like a little bitch.

[PG BOOSTED]

LOL dude just keep doing what you can. congratz

[ShadowMan]

Made a litlle more progress. You'd be surprised on how long I took getting these headlight mounts tacked in "the right" place. I threw the hood on and used my radiator as well to get the headlights mounted where I think they should be.
http://imageshack.us/a/img703/544/p1150050.jpg
http://imageshack.us/a/img715/3219/p1150051d.jpg
http://imageshack.us/a/img571/2710/p1150053.jpg
http://imageshack.us/a/img515/6165/p1160054.jpg
http://imageshack.us/a/img441/4238/p1160055a.jpg
http://imageshack.us/a/img20/4659/p1160056e.jpg
The inner brackets are a combo of custom pieces welded to sections of stock pieces.

[ShadowMan]

At this point, my overall thoughts of this project are that I definitely did not anticipate the amount of time it takes to just decide on how to solve a fabrication problem. Not to mention the time it takes to actually build it, especially without the right tools. I make what I have work though. I'm about to start work on the crash bar/bumper mount and beefing up the strut tower brace to the firewall.
I was also curious how the dipshit with the tiburon thread has only 8 replies less than I do and it was only started it a week ago. And its not even a 240, it's a Hyundai. Only on zilvia I guess. Fuck this place. hahahaha

[ShadowMan]

Got more work welding the outer portion of the the driver side tub. Had to cut and grind a little here and there but she is a little closer to being done. I know I'm not the most experienced welder but some of the inconsistency has to be due in part to the welder. Alright, I'll stop runnin my fingers. I know you pic whores are just here for the show anyway.
http://imageshack.us/a/img204/9923/p1170051b.jpg
I cut tabbed that seam that sticks straight down toward the tire and folded it over. Not sure if it was neccesary, but I did it just in case.
http://imageshack.us/a/img339/401/p1170053.jpg
http://imageshack.us/a/img40/6033/p1170052y.jpg
And I'm almost done finalizing the headlight placement, but they are oh so close.
http://imageshack.us/a/img856/5889/p1170054l.jpg
http://imageshack.us/a/img252/1292/p1170056y.jpg
http://imageshack.us/a/img233/1527/p1170057.jpg
So once I get all this mess taken care of on both sides, I think I'll be able to finally work on the bumper mount and tower brace modification. Also, just looking more into how to paint, I should have just spot removed the rust, as now it appears it's going to be a pain in the ass to do it right. I guess it is a track car, but I don't want it to look like ass out of neglect and laziness.

[ShadowMan]

Once again, as I progress forward, I also back track as well. Made quite a bit of progress on my ducting though. Made it removable as well as the upper rad/ic support. Had to remove the headlight mounts as they weren't quite right. I hate this headlight problem.
http://imageshack.us/a/img844/4898/p1190050.jpg
http://imageshack.us/a/img402/3722/p1190051l.jpg
http://imageshack.us/a/img547/8118/p1190052.jpg
http://imageshack.us/a/img577/8632/p1190055.jpg
http://imageshack.us/a/img201/6321/p1190056p.jpg
To make this upper portion removable, I had been searching for some way to make it simple. I happen the wrist pins from my old pistons when I rebuilt my motor, and wouldn't you know it, they are a perfect fit inside the 1" tubing I've been using. So I cut the uprights, welded the wrist pins in the upper portion and WHAMMO!, it works. Not perfect by any means, but neither is anything else on this project.
http://imageshack.us/a/img32/5417/p1190057q.jpg
http://imageshack.us/a/img580/9137/p1190058.jpg
Ran out of welding wire so I'm done for the night. But tomorrow should bring a lot more progress and updates.

[ShadowMan]

Made some headway today. Got a late start but managed to get a few things marked off the list. I found out my nieghbor has been hoarding a pipe bender, so I snatched that up. It's a harbor frieght edition so I don't know how it stacks up to other ones that the pros on the fabrication thread use, but it bends pipe. I can feel that I'm getting close to painting the engine bay, which is where I'm boggled. It's a track car so I'm not looking to go balls out on the paint, but I want it to be something that will last and not look hidious. If anybody has suggestions, send em my way.
Headlights mounted, again. Much better I think too.
http://imageshack.us/a/img707/6853/p1200058y.jpg
http://imageshack.us/a/img707/3746/p1200052.jpg
Nismo, shizzmo. Made my own power brace. Still need to box it in though.
http://imageshack.us/a/img803/2930/p1200053.jpg
Had to cut the mouth of the bumper to fit around the ducting, not the best but it'll work.
http://imageshack.us/a/img716/1496/p1200050d.jpg
http://imageshack.us/a/img191/2476/p1200051h.jpg
http://imageshack.us/a/img14/4306/p1200054d.jpg
Removed the cross member and all attached items which allowed me to be able to clean up alot more surface rust as well. Quite a bit more than I initially saw.
http://imageshack.us/a/img268/5566/p1200059.jpg
Started making one of the bumper bars. A little tricky getting the bends on either side to match up but I get em close enough for my taste.
http://imageshack.us/a/img706/1328/p1200056t.jpg
http://imageshack.us/a/img692/7729/p1200057.jpg
It started getting late so I'm done for now. I'm hoping by tomorrow someone will chime in on which road to take for engine bay paint/coating so I can get a start on that. Should be able to get the crash bar mocked up and tacked in place as well. No that you're done looking at my hard work, go post a comment on that asshole's tiburon thread. hahaha.

[Extreme Dimensions]

nice job on the duct system!

[ShadowMan]

Not much progress but I got the upper bumper/crash/bash bar tacked in place as well as the headlight outer mounts.
http://imageshack.us/a/img713/6448/p1220052e.jpg
http://imageshack.us/a/img11/4937/p1220058.jpg
http://imageshack.us/a/img9/9162/p1220053l.jpg
http://imageshack.us/a/img255/687/p1220054.jpg
Not sure if this was the best way to go about it. I will try and weld in a stiffener plate in the frame rail itself to tie the inner and outer angle iron together. One of the reasons I did it this way is hoping that in a bad crash it will allow more shearing/crumpling with mounts on the outside rather than on the end of the frame rail. Maybe I'm way off base as I have no personal experience in this matter, here's hoping I'll never find out.
The headlight brackets. As you can see, I used a combo of the original brackets that bolt to the HL's themselves and some fabbed up shit that serves the purpose.
http://imageshack.us/a/img341/229/p1220055.jpg

I'll try to get the lower bar mocked up tomorrow, but I think I'm going to make that one removable as it seems like some more experienced fabricators have mentioned that detail for ease of trailering the car. Thanks for looking.

[ShadowMan]

Got home and was able to get the lower bar bent and welded on before the wife had to leave for school. Going to make this removable to, but I think I'll keep the upper bar permanent.
http://imageshack.us/a/img856/1486/p1230059.jpg
http://imageshack.us/a/img844/6195/p1230057g.jpg
Seems to be coming along. I should be able some more done tonight. I think I'll pull the dash out and remove the ac stuff and weld up those holes as well.

[ShadowMan]

Probably more pics than neccesary but here ya go.
Boxed in the "fismo" power brace. I think my welds are finally getting better as far as dialing in the welder, just need to work on welding straighter.
http://imageshack.us/a/img109/5706/p1230057q.jpg
http://imageshack.us/a/img267/1486/p1230059.jpg
http://imageshack.us/a/img600/3807/p1230060z.jpg
Modified the strut tower brace. It's not completely finished, but the just of the idea is there.
http://imageshack.us/a/img11/5195/p1230061.jpg
http://imageshack.us/a/img201/8443/p1230062.jpg
http://imageshack.us/a/img545/3531/p1230063.jpg
Welded this plate on the firewall where the tower brace will bolt up to, although I'm not sure it's enough on its own. Probably going weld something in behind there under the winshield wiper. Just not sure how I'm going to do it. That part of the firewall isn't sturdy enough for me so I'll have to get creative and go overboard as usual.
http://imageshack.us/a/img10/4956/p1230064t.jpg
And a gratuitous shot of tonights work dudebro'n it up.
http://imageshack.us/a/img707/1663/p1230065.jpg
I've also come to terms with the fact that this build isn't as sketchy as I thought, because of the lack of shit talkers leaving their humorous smack talk. But on the other side, it also lacks that "special sauce" that gets everyone "e-jizzing" all over it. So I'm content with an in the middle build. Maybe once I exit the military, I'll go beg for a job at an automotive fab shop. That way I can learn how to do this shit the right way, instead of the "well I'm tired of staring at it, so I'm just going to weld this here, and that there, I guess it's good enough" way that I'm currently using.
As always, thanks for looking.

[PG BOOSTED]

Nice dude your getting there.

[ShadowMan]

Got just a few things done, not much tho.
Stitch welded some more seams
http://imageshack.us/a/img831/7831/p1240058.jpg
Then I braced/stiffened my 3 poit strut brace
http://imageshack.us/a/img651/6255/p1240059k.jpg
hopefully i'll be able to get more stuff done tonight, i just need to figure out what is needed to get this bay painted. I heard at one of my local meets awhile back that if I'm going to track the car that i should tie the strut towers to the firewall. Not sure if my brace meets that requirement or if i should weld permanent braces from the towers to the firewall. I'm probably doing too much at this point.

[ShadowMan]

Seeing how this build is already above and beyond my initial intentions, and I'm getting pressed for time and money, I'm thinking of just using POR15 for the entire bay instead of paint. This is no show car and far from impressive anyway, so I'm thinking this is the most cost effective and durable route to take. But if it's a bad idea, I'm willing to listen to reason. It "seems" to be a great choice, pretty forgiving in the prep work and its durable, so it should handle the abuse of removing and installing the motor multiple times. Plus I won't be butthurt if I ding it like I would if I took the time to properly paint it. I'm not set on it yet tho, I swear.

[Taylor008]

I was supposed to be asleep 20 minutes ago but I had to read your damn thread.

Stop making it so cool.

I want your ducting. Keep going, this build rocks.

[ShadowMan]

I was supposed to be asleep 20 minutes ago but I had to read your damn thread.

Stop making it so cool.

I want your ducting. Keep going, this build rocks.

Thanks for the compliment. I know how you feel, getting hooked on other peoples thread til the wee hours of the morning.
Also decided how I want to tie in the outer frame with the Rad/IC core support. Now that I've got it in there, it seemed like the obvious answer along, I just couldn't see it. I guess that shows me inexperience, but I'd like to think I'm slowly getting this fab stuff figured out.
http://imageshack.us/a/img22/8232/p1250063.jpg
http://imageshack.us/a/img9/4666/p1250062.jpg
I'll get better pictures once I get both sides in place. But I think this is a step in the right direction towards getting the bay painted.

[brndck]

Cool project. I would way rather read a thread like this than just another "stance" build.

[dazed]

Wow man, this is some good stuff. You did some good work on that tube front for just angle cutting with no pipe-bender. Keep it up, interested to see where this goes.

[ShadowMan]

BRNDCK-Yeah, I really want to race it, probably drift/autocross as best I can for an all around ride. I have 800 for race sprares and tires, so I'm thinking, still looking.

[ShadowMan]

dazed-i wasnt sure at first but it seems to be coming together now. Thankyou

[ShadowMan]

Got a bit more done today. Also used some scraps to make a table, which would have been nice to have all along, but what can you do?
The table
http://imageshack.us/a/img189/2319/p1260068y.jpg
And the front 98% finished
http://imageshack.us/a/img541/4301/p1260066.jpg
http://imageshack.us/a/img266/2047/p1260067.jpg
http://imageshack.us/a/img21/2810/p1260069v.jpg
Also welded up some unneccesary holes in the bay. Just need to throw on a few more welds, a couple tabs to mount the PS resevoir-coolant overflow-FPR, and then just a bit of grinding here and there. Also got the all the stuff to POR15 everything, which I'm hopeful will happen tomorrow.

[KiLLeR2001]

I was going to POR15 my bay and then decided against it. Not because its a bad idea but because I know I'd want a shiny awesome looking bay that matches the exterior color as well. Interested to see how it turns out though.

[ShadowMan]

Well, I'm going to see how it looks, and if I don't like it then I'll paint it. Everything I've read says it will take any kind of paint, and a top coat will protect it from UV damage anyway. Not that the bay is at any risk from UV damage, but we'll see. I'm getting excited to see how this turns out. Not sure if I should stay with one color or try and be creative. Can't wait for tomorrow.

[Mikester]

Dude, just got done reading this thread- that's some really good work!

As far as the engine bay POR 15/paint cunundrum, may I recommend you drop jr_ss a PM... He could tell you in pretty great detail what the different tradeoffs will be. He's helped me with a few prep/paint issues... Very knowledgeable dude.

[pablo13]

I wouldn't worry too much. I POR15 my bay then primed and painted and lacquered on top and it came out fine.

Looks great so far, keep it up :)

[jr_ss]

POR15 is typically not sandable. Infact, if I recall correctly it is not. So if you plan on sanding the bay/tubes/whatever, you will need to use a filler primer to be able to get the "smooth" finish you would like. I'm not sure exactly what your goals are, but most people in general like a clean bay. I would POR15 it and see how YOU like the finish. I've found that it creates a pretty decent finish if it's thinned and applied correctly. However, I'm not a fan of "black" engine bays, so I'd be adding color on top if it were me.

[ShadowMan]

I'm thinking I'll just POR15 all the bare metal, see how it looks, post some pics so others can decide if it's a road they want to take. If I don't like it, then I'll paint it the next time I take the engine out. Some good news though, the guy I bought the car from finally got back to me about some questions I had. For those that haven't read the entire build, I was unsure as to the brand and size of my injectors, got it tuned enough that the afr's were fine but wasn't a solid tune. Turns out they are Blitz 850cc's, so I'm confident I have all the fuel i need for now. But he also informed me the rear diff is a stock unit. I never checked it out because I haven't ever had time to get back that far, regardless I need to source at least a 1.5 way lsd. I'll take donations (hahaha) or more likely a heads up on an affordable unit if anyone sees one for sale. Sorry, no car pics on this update, but I'll leave this here for now.
http://imageshack.us/a/img834/6382/pb130341.jpg
One of my buddies, slaying bodies.

[ShadowMan]

Well I've been browsing thru the for sale thread for a 2 way lsd and found some prospects. I think I'll go with kaaz as they're stateside and rebuildable. I'm on the fence between one for $600 with about 8,000 miles and 4-5 track days, or just a brand new unit for $800. I'll make my decision in a day or two and make the purchase. That and a hi pressure power steering lines are all I think I need so hopefully I'll be ready to go as soon as I'm done with the bay. I think I'm going to set the motor in the bay for a final mock up of where the last items will fit into the bay as well as measure for IC pipe lengths and what not. If the pros do it, then it can't be a bad idea. That's it for now.

[brndck]

kaaz are extremely durable. i wouldn't hesitate to get the used one.

theres a place nearby called rupe's that builds hydraulic lines. they fixed my high pressure line when one of the fittings broke, had it done literally in under 10 minutes.

[ShadowMan]

kaaz are extremely durable. i wouldn't hesitate to get the used one.

theres a place nearby called rupe's that builds hydraulic lines. they fixed my high pressure line when one of the fittings broke, had it done literally in under 10 minutes.

Thanks, I think I will get the used unit and use the extra money on a new clutch maybe. Once it's time to put this together, it "should" go quickly, I hope.

[ShadowMan]

Well, I decided to do a final fit/mock up to see if I forgot anything. Just a few more tabs to weld in for the PS resevoir, oil catch can, EBC solenoid, and a few others. I can also mock up to IC piping, and take the IC to see how much it'll be to get modified. I also need to get a new intake pipe as well. Come to think of it, there is still a lot to do, so here's the pics.
Boxed in these bad boys.
http://imageshack.us/a/img94/3351/p2020068.jpg
The o-ring was obliterated on the brake master cylinder, which led to it leaking every where which is what caused everything to rust. The booster got it bad.
http://imageshack.us/a/img255/4148/p2020069.jpg
I like the way it looks without paint, even with all fab scars and sketchy welds too.
http://imageshack.us/a/img90/2341/p2020070.jpg
http://imageshack.us/a/img651/2125/p2020071.jpg
Can't wait until I can re-build this the right way with beefier guts.
http://imageshack.us/a/img28/9490/p1280066.jpg
And nestled back in its home
http://imageshack.us/a/img18/5474/p2030072.jpg
Tomorrow I should get the wiring all back together but we will see.

[Sansone]

Looks awesome. It would be kind of neat to just clear coat that bay as is! lol

[ShadowMan]

I've been seriously thinking about it. I wouldn't be worried if the non existent paint got messed up, and I would be able to see rust early on so it wouldn't be able to get as bad as it did. I like the way this looks, don't know why, but I do.

[ShadowMan]

Was able to make some more progress on the little things, which is nice because the list of shit to do gets shorter fast. Mostly just getting things mounted.
Radiator overflow.
http://imageshack.us/a/img502/2374/p2030066.jpg
http://imageshack.us/a/img811/4870/p2030069.jpg
http://imageshack.us/a/img818/5474/p2030072.jpg
Catch can
http://imageshack.us/a/img23/1173/p2030068.jpg
http://imageshack.us/a/img26/8314/p2030075.jpg
FPR
http://imageshack.us/a/img7/1713/p2030074.jpg
This picture shows the path the cold pipe will have to take.
http://imageshack.us/a/img585/3884/p2030073.jpg
This pic shows the path of the hot pipe.
http://imageshack.us/a/img145/1619/p2030071.jpg
I need to find a welding shop that will modify the end tanks/outlets so they are orientated as directly to their link up points as possble. Hopefully, it'll be affordable or I may just buy a PBM hi/mid mount unit.
Need to lengthen the injector plugs so I can route em underneath the IM.
http://imageshack.us/a/img534/4803/p2030077v.jpg
And an end of progress for the weekend pic.
http://imageshack.us/a/img401/493/p2030076.jpg
Still lots to do. I just barely started running the wires to their locations and haven't even began to solve the mounting of the fuses/relays/connections under the dash/in the glove box problem. I need to pick up my kaaz lsd too and get that in. Lots more to do, but I cna taste it.

[dawagarage]

diiiig. damn man, i wish you coulda did my tubed front end

[ShadowMan]

I've been a little distracted but I managed ot get a few more items scratched off the to-do list. Mounted the fuse/relay box, modified my intercooler, and fabbed up some mounting points for the toe arm brackets, and soldered up some wires that needed some attention. Can't wait to get this hog started again.
I know this is a mess, but I'll sort it out. Just need to start figuring out a good location.
http://imageshack.us/a/img577/8150/p2060070.jpg
Next up was modifying the intercooler. My reasoning behind this route was saving money, I hope. I figured this way it would cost me 50-100 bucks to have a shop just weld this up as opposed to buying a new intercooler. Plus, it just gave me more of an option to customize how I want it. It took me a little bit of staring to finally just cut into a perfectly fine IC, but too late now. The piping is the cold pipe for the freddy that I hacked up.
Cold Side:
Test fitting the cold pipe, trying to decide my attack plan.
http://imageshack.us/a/img19/6391/p2060066.jpg
http://imageshack.us/a/img835/7215/p2060067.jpg
Trimming the pipe
http://imageshack.us/a/img560/2457/p2080073m.jpg
http://imageshack.us/a/img541/5421/p2080074.jpg
http://imageshack.us/a/img507/3036/p2080075.jpg
Cutting the IC
http://imageshack.us/a/img521/1792/p2080076.jpg
http://imageshack.us/a/img831/6488/p2080077z.jpg
http://imageshack.us/a/img803/8648/p2080078.jpg
http://imageshack.us/a/img802/5673/p2080080.jpg
http://imageshack.us/a/img24/5967/p2080081.jpg
Hot Side:
http://imageshack.us/a/img259/5517/p2080083.jpg
http://imageshack.us/a/img10/8218/p2080084.jpg
http://imageshack.us/a/img198/7624/p2080085.jpg
http://imageshack.us/a/img11/7107/p2080086a.jpg
http://imageshack.us/a/img689/7151/p2080088w.jpg
http://imageshack.us/a/img839/7260/p2080089z.jpg
http://imageshack.us/a/img26/599/p2080091.jpg
http://imageshack.us/a/img194/1434/p2080092.jpg
Mocked up with Radiator
http://imageshack.us/a/img585/6828/p2080093.jpg
http://imageshack.us/a/img843/998/p2080095.jpg
http://imageshack.us/a/img571/6401/p2080096.jpg
http://imageshack.us/a/img94/9882/p2080097.jpg
http://imageshack.us/a/img822/4848/p2080098.jpg
In the car
http://imageshack.us/a/img856/9827/p2080101.jpg
Bracket mounts
http://imageshack.us/a/img546/4676/p2080100.jpg
http://imageshack.us/a/img259/6966/p2080099.jpg
gratuitous end of day shot
http://imageshack.us/a/img10/4091/p2080102.jpg
Over all, it's definitely not the slickest layout, but I think it works. A good track day ought to help shake it down tho. Definitely some things I would do differently but I'm satisfied with it.

[oni jake]

What the hell. That hack job on the intercooler is one-way thinking. Take a band saw and cut the end tanks off. Build from there.

Otherwise, lots of potential! I can't wait to see it done.

[ShadowMan]

What the hell. That hack job on the intercooler is one-way thinking. Take a band saw and cut the end tanks off. Build from there.

Otherwise, lots of potential! I can't wait to see it done.

I would have liked to build all new end tanks, but I don't have the material or the ability to weld aluminum. I;m hoping this way I can take the radiator and intercooler to a shop and just have them weld it for like 50 bucks since I've done 90% of the prep work. I won't disagree with you that it is a hack job, but come to see how it turns out, maybe it will look better once it's welded and cleaned up.

[oni jake]

Aren't you in the military? You're telling me you don't have access to an aluminum welder? Auto Hobby? Vehicle Maintenance? Anything?

I know you're trying to save money, but man... I'm getting tense just thinking about that IC.

[ShadowMan]

There is only one automotive shop on Pendleton and no, they don't have an aluminum welder. They have one mig that's more beat up than a hooker from Thailand. They wouldn't even give me shop suggestions because of whatever beaurcratic reasons of not favoring shops. I just dropped it off today at warners muffler and it'll run me $120 for everything I need done to it. At this point, I'll be happy if I take it to the track and the motor I built doesn't explode, and the front end I tubbed and tubed doesn't fold on the first corner. I have no experience in any of this, so everything I do is a lesson learned. Worst case with the intercooler is I get new end tanks for it when I have the money. As far as progress today, I got the wheel wells prepped for the POR15. So that'll be done by the end of the weekend. Then I can put the front wheels back on, put the ass up in the air and get the KAAZ 2 way installed. I'll snap some pics and post them up because I'm often butthurt when people don't throw pictures up in their builds on an update.

[ShadowMan]

Alright back with pictures. This is just of the passenger side but I'm sure you guys can pretend both sides look like this. Quick run down of the process:
1-Wire cup and angle grinder to get down to bare metal
2-Aircraft paint stripper for the nooks and crannies
3-Marine Clean diluted 1 to 5 with hot water
4-Rinse thoruoghly with water
5-Prep and Ready spray down, kept wet for 30 mintues.
6-Dried thoroughly.
SO now it's ready for POR-15 I guess, just not sure if it supposed to look like it does.
So here it is after the wire wheel.
http://imageshack.us/a/img145/369/p2090066.jpg
And this is after the marine clean and prep n' ready.
http://imageshack.us/a/img109/6057/p2090068.jpg
http://imageshack.us/a/img856/884/p2090067.jpg
http://imageshack.us/a/img32/2231/p2090069.jpg
http://imageshack.us/a/img266/8914/p2090070.jpg
Wish I had a paint gun or two, then I'd just paint it. But I think por15 will do good in the fender wells. We will see tomorrow I guess.

[ShadowMan]

Well I got the wheel wells coated. Inspected the kaaz lsd I bought as well, never seen one before so I'm not sure if it should say kaaz on it somewhere or not. Everytime I google it, I get directed to honda forums, or people asking which is better, so I leave it to one of you guys to help me out if you can. I spun it inside housing expecting to see a big KAAZ stamped on it, oh well, here's some pictures.
The KAAZ 2 way
http://imageshack.us/a/img89/9871/p2100070k.jpg
http://imageshack.us/a/img14/1781/p2100071.jpg
The wheel welss after 1 coat of POR15
http://imageshack.us/a/img571/3625/p2100066.jpg
http://imageshack.us/a/img96/3366/p2100067.jpg
http://imageshack.us/a/img585/2246/p2100068.jpg
She's coming along I guess.

[ShadowMan]

I was able to swing by and snatch up my intercooler and some extra piping as well. Turned out decent for what I handed him, so no complaints from me. When I have extra money to throw around, I'll probably end up changing it with some other things as well. Should be able to finish up the minor gaps in the ducting and get the front fully assembled by tonight hopefully. Maybe even get the new fluids put in but I'm not trying to rush that step.
Modified intercooler
http://imageshack.us/a/img694/2071/p2120066.jpg
http://imageshack.us/a/img23/7539/p2120067.jpg
Here's the roughest side
http://imageshack.us/a/img252/5972/p2120068.jpg
Cannabalized some old IC piping
http://imageshack.us/a/img9/9251/p2120069.jpg
New end welded on
http://imageshack.us/a/img255/3787/p2120070.jpg
Not too much burn thru
http://imageshack.us/a/img850/5713/p2120071m.jpg
Gap in the ducting
http://imageshack.us/a/img829/1158/p2120072t.jpg
Piece to block it off
http://imageshack.us/a/img703/3458/p2120075.jpg
All these minor odds and ends add up. Wish I had someone to show me the in's and out's of this shit. I'm pretty sure I'm going about this all wrong in the hardest way possible.

[ShadowMan]

My damn camera broke so pictures will come later. I did manage to get a few things done today that put me on the verge of starting this pig.
Flushed and mounted IC and piping
Made mounting tabs for the ducting and upper rad support
Intake mounted
BOV mounted
Fuel lines tightened up
Clutch slave mounted
Still need to get a few more essentials done before I turn the key
Fill the fluids
Reinstall the dash, again.
Finish soldering some ground wires up
And some other shit that will pester me I'm sure.
There were a few other odds and ends that got finished as well. I need to get a camera so you guys can see all my hooptie ass progress. It will be nice to get this finished so my wife can stop calling me a coal miner as well. Been a while since I've been this dirty.

[ShadowMan]

diiiig. damn man, i wish you coulda did my tubed front end

Thanks, I wish I had a decent pipe bender to get really get into this front end.

[Extreme Dimensions]

Loving the fabrication work!

[PLAYERO_LOKO]

thats a lot custom work you've done there brother, very nice and props for giving it a try!!! keep it up!

[PG BOOSTED]

Yeah man! Keep this up dude. I'm liking the fabrication.

[ShadowMan]

Thanks guys. I am glad I tired all this. Lots of lessons learned on this project that I think I'll post up just to give people a heads up who might consider tackling their first fab project. Good news is I finally fired it up tonight. I forgot how she sounded, although I believe she has more deep throaty rumble to her. There were a few hiccups but after (3) 20 second priming bumps, I plugged the ignitor in and she fired up right away.
Diiferent ways I shot myself in the foot are:
-Loosened a fuel line to move it out of the way for my banana hands and forgot to tighten it down, so the engine bay got a fuel shower.
-Forgot to tighten lower heater hose all the way, so that leaked just a bit.
-Unplugged a clip on the passenger side when dash was out so the cluster didn't work, remove dash, find clip and connect it, then re-install dash.
-Went to install gauge cluster and it wouldn't seat because of the route I chose for my wire tuck, remove dash again, adjust wire route, reinstall dash again.
-Was not as tedious in bagging and labeling nuts, bolts, screws, etc. when removing interior so now I just have a pile of hardware that I sort through when needed to find what fits.
Thats all I can think of for now. First thing tomorrow is bleed the brakes and clutch, install headlights and get her rolling aorund to see what may decide to leak. After that its on to the fenders, bumper and kaaz 2 way. I'm hoping for a 99% complete car by tomorrows end, then just a few highway shakedown runs to put my mind at ease that she will last a track weekend. I will get pictures up as soon as I can.

[izzy-]

Great build!
But, your welds are bipolar. Some good, some bad. You should do some test runs on scrap metal, and when they look like your stacking dimes, then you should go for it. Not hating, just advice. :)
Congrats on your baby!

[ShadowMan]

Great build!
But, your welds are bipolar. Some good, some bad. You should do some test runs on scrap metal, and when they look like your stacking dimes, then you should go for it. Not hating, just advice. :)
Congrats on your baby!

No offense taken, I always enjoy critques and criticism. I completely agree with you on practicing. Should have done alot more. It didn't help that I started off using my neighbors harbor freight welder with flux core wire, that had only 4 settings for temperature. I also learned that I need to tell my wife that she can't do laundry while I'm welding, and lastly that I should not have used an extension chord that was smaller than the welders chord. All that combined just led to inescapable inconsistency. I probably have spent twice the amount of time grinding than I did welding. I would practice a few runs each day, and once I thought they looked decent enough, I had my go on the car,but my inexperience and the before mentioned hurdles just fought me, especially when changing between the thinner stock metal and the thicker material I added to it. It wasn't until I borrowed my buddies lincoln that I was able to lay down smoother beads which are the beads that look presentable.
On another note, camera is still broken so that sucks. I got most of the car put back together. Now it sounds like a subaru, so I need to find which cylinder has the problem. Had nasty fuel leak as well but got it fixed. And I got the kaaz installed, which was the first time I've been under the ass end of my car, so many spider webs, I swear. Only took me about 1.5 hours to get the old diff out and the new one in, so not bad overall for the first time swapping one ofe those out. Still need to put the hood, fenders and front bumper on and figure out how I'm going to secure them. And lastly, non of my cluster is working. My low fuel light is on but the tach doesn't work, temp gauge doesn't work, and as I haven't driven it around yet, I'll assmue the speedo won't be working either. So I'm kind of demotivated right now to even try to begin to solve these new problems. So, you could say I'm super butthurt right now.

[ShadowMan]

Alright, so I got most of those issues sorted out. Bad cylinder was do to a loose wire on the injector clip on cyl#4. Repinned it in and she's purring like a champ. Everything in the cluster works except the tach, and I haven't tried sorting that out yet, if anybody has a suggestion, I'm all ears. Just need to bleed the brakes and clutch and put the body parts back on, then spend the rest of the week nuttin and boltin everything all over again. Glad I was able to fix most of the shit and wipe some of the butthurt away.

[elnino335]

just finished reading this and its making me want to go start welding my own tube frame

[Sstrappjr]

Great build so far!

[ShadowMan]

Elnino335-That motoivation bug is the devil, be careful. lol. I am glad I did it because I learned so much from everything, mostly from doing things wrong but now I know, and I'm all about others going for it. Any questions you have, I'd be glad to help answer if I can.

Sstrappjr-Thanks, I appreciate that.

[ShadowMan]

Update time. Was able to get the car back together and running in time for a track weekend. Pretty happy about how everything went down, especially for my first time with this car on a track. I do not own a truck or trailer and could not find one to borrow and couln't afford to rent one. So I packed everything I thought I would need and then some into the hatch and drove it from Pendleton up to Willow Springs for a Just Drift event. I beat the hell out of it all weekend long, and i mean I really laid into her. I held back only slightly because I knew I had to drive it home. Day 1 was me just getting used to the car, attempting donuts, figure 8's for the first half of the day, then wide sweeping drifts for the second half on the Balcony track. Didn't hit the dirt to much except when I went shallow into the back turn. 2nd day was at the Horse thief mile track and a bit more nerve racking, especially trying to link the drifts. Did quite a bit of off roading that day. I let one of the intructors drive my car and even he hit the dirt. But with all the advice and tips from any and everyone I talked to I think I progressed alright. I'd post some videos, but they are not nearly as rad as some of you guys who just link them turns in third gear with more smoke than a cheech and chong movie bellowing of your tires, so I think I'll wait until I have some good stuff to show you. Only casualties of the weekend was a passenger tie rod, the lower crash bar, the fenders cracked more, and the exhaust took a beating as well. The car just had so much grip as it would just hook and rocket off the track. I was running a set of continentals in the rear, 245/40's and they lasted both days. They are down to the wires now but never popped, so I have a butt load of tires for the next event. I also need to throw on some negative camber with wider tires in the front. But even after all that I was still able to drive it the 3 hours back home to pendleton. My wife followed me there and back in our hyundai and called me once we were on the road to let me know about the sparks my exhaust would shower her with when ever I hit a bump. Still don't have a new camera yet but as soon as I do, I'll get some pics up. That's all for now.

[lewisfk]

Hey man just picked up a welder and trailer fender from etrailer. I'm about to give it a try tomorrow. I'm on PTAD for 15 days, I aslo received my ARC wiring system for the chassis, what problems did u run into using the painless system?

[ShadowMan]

Oh I didn't use the painless system, I used the extremely long and painful, make-me-all-butthurt system. haha. so I don't know. Just label the shit out of everything. As far as welding, fitment is everything. It's 90% in the prep work.

[PG BOOSTED]

Hey man, i sell parts now. At a decent discount, hit me up if you need anything.

[Wizard]

awesome build so far just read through it i love all the custom fab work you need some new pics! its too hard for me to read what youve done haha

[drscooper]

the tube looks great man. learn everything now, drift it for a year and then re do it when you have cash saved up.

but great work none the less really like the duct work.

[ShadowMan]

Wizard- I hear ya, I'm all about the pics myself. Thanks for browsing thru it tho.
drscooper-You hit the nail on the head. That was basically the conclusion I came to after the weekend at willow springs. I just hope the car survives the abuse I put it thru, I've become rather attached to it after all this hard work.

My camera just decided to start working again, but I still need to get a new one that can produce better quality pictures. Here's a few for to keep you guys intersted tho.

The front took some abuse sliding off the track and I lost the lower crash bar, not that it was all that sturdy anyway.
http://imageshack.us/a/img341/6412/p4060066.jpg
Passenger fender tooka good beating too.
http://imageshack.us/a/img833/7162/p4060067.jpg
Front passenger tire decided to finally give up when I was driving home. I was about 10 minutes from my house when it happened. Thankfully I had a car loaded with all the goods to get it changed out.
http://imageshack.us/a/img803/6320/p4060073.jpg
Here's what's left of the rear tires. I bought these used with about 60% tread left and they lasted the entire weekend, never had to change tires until it was time to drive home. They're continental contacts 17" 245/40's. Too wide and too much grip from what the intructors told me, as well as the car just ctaching grip halfway thru some of the drifts and slinging me into the dirt.
http://imageshack.us/a/img854/1772/p4060075l.jpg
And the engine bay, I never painted or clear coated and being out here on pendleton, there was a few foggy/rainy days that led to some surface rust. I'm not worried though as I'll be moving up to Montana soon and there will be plenty of winter time to pull the motor and redo some mistakes and get a coat of something on her.
http://imageshack.us/a/img812/1182/p4060072.jpg
http://imageshack.us/a/img341/917/p4060071.jpg
http://imageshack.us/a/img339/2479/p4060070.jpg
As always, I appreciate you guys looking thru this and always welcome comments/critiques/criticism. Thanks.

[ShadowMan]

I also have to confess to a boot ass mistake I made. One of the many times I slid off the track, I broke a tie rod. Pit space was at a premium and I was parked next to the orange vert you see in the beginning of this video. Well I positioned my jack to get my car up and did not tighten the handle all the way (very stupid) which left it at the mercy of the wind. Which in turn left this guys really nice and clean vert at the mercy of my jack handle. As I let go of the handle and turned to grab my tools, I heard the most sickening thud I heard all day, even when I was mowing dirt. I knew what happened before I even looked at it. The handle to my jack fell into this guys door and took a chip of paint out about the size of a thumb nail. When I did look I got that queezy feeling you get right before you usually vomit. Took me some time to track him down to let him know about it. I wish I could remember his name, especially since he was non chalant about it being a drift car and it didn't matter. Seriously, he was very cool about the whole thing, even turned down the set of wrenches I bought him as an apology. The rubber protective grip was long gone from the handle so I instantly wrapped a roll of e-tape on it to keep it from happening again. Even tho it was my first track day and all, it was a stupid mistake. So to everyone that sees this car and the ding in the driver side door, yeah, that was me. But this video also shows the more advanced guys that were out there getting sideways, including him. Some pretty good talent out there, better than me anyways. I'll see if I can find my best video to post up of myself, just so we can all have a laugh at me scrubbing dirt. And to the cool headed man with this orange vert, if you ever read this thread, again, I'm sorry about your door.
63545057

[ShadowMan]

Here is a run from the 2nd day on the HTM track at Willow. That last turn with the pit exit ate me up all day. This run, I was lucky enough to keep it on the pavement, but most of the time I ended up on the inside mobbing around like a trophy truck. Some of my friends still can't believe I beat my car up like this after all the work I put in, but I had a good time. I know I need to go faster and the track looks wide as shit from this angle, but driving on it, it feels like it's as wide as a golf cart track. I will also say I have an awesome wife for toting our two boys, 6 yrs old and 6 months old, for 2 days and filming almost every run for me. She and the boys were real troopers keeping an upbeat mindset the whole weekend while I was the one having fun.
63628378
I know it isn't much, or fast or very good, but this was my first weekend of drifting. I've never been street drifting or parking lot drifting or anything, so that's why I suck so bad. But I have a better understanding of what a big difference wheel and tire setups can do, camber, etc....so hopefully next time will be better.

[ShadowMan]

I tried to break this video down into smaller segments, but I'm really not computer literate, and my computer sucks. Anyways, this video is from the 1st day at the Balcony. It's the second half of the day, where we all just took turns making these runs.
At 3:00 the driver in the white hatch is 15 year old kid. It's a stock ka, and the kid put together better runs than I did. He's also been doing it for a year or so, but regardless, he has some talent. Him and his dad helped me out when I busted my tie rod. I would have let him make a run in my car if I could have risked it, but I needed it in one piece for the drive home, but maybe next time. There were also these other two guys parked on the side opposite of John Chow, so their cars were safe from my jack handle. They offered up parts as well, they ended up being the wrong size but they tried. They both had ls swaps as did others, and man those things sound mean in person. It's awesome to hear a 240 rumble like that

As for these videos, I'm really just posting these videos to give anyone else thinking about starting all this an idea of what to expect. Unless you were blessed as one of those people who can just try something and get it figured quick, fast and in a hurry, then like the rest of us mortals don't expect to be busting out face melting, super linked drifts on your first weekend. Bring your determination, good attitude and a solid car and you'll have a blast.
63773950
OK, you can laugh at my expense now.

[brndck]

orange vert = john chow. cool dude.

[ShadowMan]

Thankyou brndck. John Chow, Thankyou for being cool with me about your door.

[ShadowMan]

Alright, I'll have to up load the videos later, but went to the Balcony at Willow for another Just Drift weekend. Had a great time despite the heat, sunburns, sleeping in the truck, yada yada. Had a truck and trailer this time so I wasn't too concerned with baby'ing the car. Getting closer to being able to link my drifts and upping the the speed as well. I think I have a bit of begginers luck on my side with this motor, it gives me just enough problems to keep me giving it attention. Casualties of the weekend-fuel feed line detached itself, split intake pipe coupler, 2 flat front tires, tapped the wall with back passnger corner, and what else.....oh yeah, the motor went all david blaine by making one of the throttle plate screws come out and dissappear. It seriously vanished, it's not in the intake piping, the intake mani, and it didn't sound like it was in the motor itself when I dry fired it. So I ran the motor the whole rest of the weekend with no problems, it actually ran better, probably because I put new throttle plate screws in and tightened them down. I think thats it. All in all, had a great time.

[brndck]

I had a similar situation where my throttle plate cracked around the hole where the screw goes through. We ended up just welding it solid.

[ShadowMan]

I had a similar situation where my throttle plate cracked around the hole where the screw goes through. We ended up just welding it solid.

Any downsides you encountered to welding it? I just went and bought longer screws and used blue loctite. Not sure about the longevity of blue loctite though, because when I was just giving the car its post track tune up, I rechecked the throttle plate screws and they were loose by about 1/2 a turn. I guess I'll try loctite one more time and then go from there once it becomes overly annoying.

Question for those of you who actually read this thread:
Which spacers seem to hold up the best and how much is too much? I was thinking of 20-30mm for the fronts that have the studs pre-pressed. I usually go through frpsort for the stuff I can't get locally. They have h&r, project kics, and ichiba. I've never paid attention to wheel spacers until now so not sure which ones will hold up to drifting, autox, etc..

[elnino335]

What thickness metal sheets did you use to weld on ?