CaBS

Made this clip of one of the wiggins clamps from the SXDS15 cause lots of people are concerned the piping is solid mounted and might crack. Early days but its already seen some street driving a track day and a dyno session with no issues. There is a surprising amount of movement in them and also pull/push. 4 degrees each clamp which means with two clamps per pipe there is considerable room to move.

[media]http://youtu.be/03eiAaN2BcI[/media]

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CaBS

Went down to check out where the car was up to and throw in an old throttle cable so the tab for it can be welded onto the plenum chamber. All the intake and radiator piping has now been finished. Next up are the bleeder tanks, air box, intake pipe, catch can, p/steering res and mounting various other engine bay essentials.

The starter and wiper motor have been put back in for clearance to other things being made/installed. The drivers side has much to go in we need to plan it out to keep it as neat as possible while not being impossible to get to anything.

Pipes n stuff


Going to try and keep the satin finish if we can seal it somehow.


Because we were able to get the fmic core so far forward its created a lot of space in the engine bay which will make it so much easier to work on for years to come.


Hypertune hand crafted bleeder tank. We were initially going to use the factory elbow off the head into a tank but the elbow itself angled down slightly meaning there was a high point for bubbles to get trapped in. This new one angles upwards to help solve that. This will have a -3 fitting on it over to the bleeder tank high up on the drivers tower to remove as much air from the system as possible.


Tight fitment in here with lots of weld.


Rad hardpipes complete.


Engine bay is really starting to come together, should be much more complete over the next fortnight.


More soon!

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smoked240

That's exactly how I want my IC piping to be. Fucking bravo!

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CaBS

Thanks man

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CaBS

Some more progress this week.

Bleeder tank for the coolant system is mostly done the top just needs to be welded on.


Billet speedflow head on it nice and neat.


Uses preexisting threads in the tower. The old cusco brake master stopper used to mount here so we'll make another which comes off the strut brace further down the track.


Basic shape of the air box folded up out of alloy.


We've run into an issue cause the motor is sitting so far back in that its fouling on the plenum. Usually this would be a simple notching job but in this case its lining up with the flange of the plenum so this makes it much more of a headache.


I've heard a rumor the CA18 clutch master is abit smaller. Not sure if anyone can confirm this? I need something 15mm-20mm shorter than the factory SR one which is just under 100mm long.


Drew up and folded up a cardboard template for the oil filter relocation block.


Should get a chance to cut it out of alloy this week and have a go at folding it up. I can then bolt the block to the box before screwing the box onto the rail.



More soon!

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future

Beautiful


myposttooshort

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Royal_T

Love the build bro and the quality of work going into it... Keep it up..

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scottie

I am pretty sure this is truly car porn. Each time I scroll through this thread I feel ashamed.

PrimeDirective

How much do you expect the engine to move? It looks like you have plenty of clearance between the intake plenum and the clutch master when I look at the side picture.

CaBS

If you look at the top down picture you can see where the manifold is sitting compared to where the head flange is. One whole bolt hole further forward. So with the 8mm gap in these pics is actually a -12mm(ish) gap when the flanges line up.

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PrimeDirective

Oh, I see it now. AP makes one that is 80mm long. I don't know the dimensions of the oem cylinder so I can't tell if the flange holes will line up or what.

http://www.apracing.com/Drawings/CP4623-cd.pdf

CaBS

Thanks man< i'd actually found that one also but needed to run the remote res cause it comes up under the lip on the firewall otherwise. I had a better look into the nissan stuff and found an S15 one which fits!

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CaBS

Had a few wins this week. After spending some time looking for clutch master solutions I came across a photo online of an S15 master which was actually off ebay from just japs page. I ran them and they had one in stock and were kind enough to measure it for me. Looked like it was going to solve my issue while still having the reservoir clear the lip on the firewall so I drove down and grabbed one.

Win was really happy when I got it in there and it'll solve the issue with no further modification what so ever.


Happy we dont have to waste any time on this now.


Here is the template traced onto an off cut of 2.5mm alloy and cut out with the guillotine as far as I could. Still had to chop out the scribbled sections with the angle grinder and then clean them up with the linsher.


Scolloped out the corners slightly to help it fold more easily.


Chris managed to fold up all but one of the tabs for me which I did in the vice afterwards. Much like a brain teaser working out which order to fold it in so the next fold is possible. Now the re-locator block bolts on through the back side of the bracket which can then be bolted to the rail.


Plastic peeled off, just needs the corners to be welded up this week and some holes/rivnuts to be put in the rail to mount it.



More soon.

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PrimeDirective

Updates???

CaBS

Soon, busy buying somewhere to house myself and the car atm

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Imarvin240

my house is always available for your cars to stay at, I don't even need the keys...but it would be a plus

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rv_zenki

Just read every page. Amazing craftsmanship! I love that no corners are cut and you use quality everything lol. I cant wait for more updates!

CaBS

I dont think the keys to this one would do you much good yet!

Thanks man.

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CaBS

Long time between updates. I've had so much going on this year there has been little spare time for the car. The next six months is looking the same. Happy to get a few hours here and there to chip away on the long list and get some stuff done.

Turbo/manifold assembly now all welded up with elbow for the hot pipe.


Needed to make this low profile plate out of some thin aluminum sheet with counter sunk holes.


Can see the high difference saves quite afew mm of space and lets us sit the gearbox closer to the chassis. Benefits being the motor sits flatter and tucks the gearbox much more neatly up under the car.


Should do the trick


Mitch zapped the corners of my little oil relocator mounting block for me.


Will be sitting neatly here away from the tyre and rearwards of the splitter mounts welded onto the front of the rails.


One of the issues we noticed once I'd modified the shifter bracket I bought so it actually fitted the car, was that on gear changes it was flexing substantially. Because there is no support for it you could put it in gear and feel the bracket flex, without slamming it into gear which it might see some of in its life. =)

So I made these gussets out of steel sheet to brace the weak points. Seen here with all the scale and chromium coating linished off (or so I thought)


It welded slightly average cause I hadn't quite got all the chromium off


Should get the trick done regardless though still needs some finishing up with the linisher. I'll do this when I get a chance.


We decided to remove the mesh out of the rear of the front guards which had to be done carefully as they are epoxied on pretty comprehensively. Reason being to let more out and I think it looks pretty cheap and shitty.


At the same time the plan was to open up these rear vents to make them more effective at evacuating air and look a bit more aggressive.


Probably not a huge difference but I prefer the look of it opened up and technically its better aero. Still needs some more sanding but you can see the difference between the bottom half which is almost done and the top half which is untouched.


Drivers side de-meshed ready to go next time.


Spent the next Friday arvo working on a design for a billet bracket for the battery. The aim of which being neat will still give access to the balance charge point without removing it, strong and pretty. =)


More soon.

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FourtyKid

Nice work!

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aga

epic build!

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KoukiMonsta

is that a custom PS pump bracket? looks cool, i made one to do that same job but have been wanting to re-do it and improve my design.

CaBS

Yeh it is from taarks. But I think it could be better there is a surprisingly larger amount of flex in it.

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Bleakley

Just read through the ENTIRE thread. Pretty much speechlees. Always interested to see other people's setups to give me ideas and to confirm ones that I have had.
One thing I do have to say is Mitch, the welder, deserves a f***ing raise. Probably the best I have seen.

tayloray

It was incredibly depressing to get to the last page of this awesome build. Hope to see the final product soon.

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CaBS

So its been a very productive few weeks and lots has been done. Fab work is very near complete now.

Tomei oil block was installed so we had a clear idea of where the lines would be coming out into the engine bay.


Quite a neat bit of billet gear. =)


Swirl pot was finished off with this sturdy bracket onto head for support.


Airbox is now complete with a pod filter inside it. Its hard to believe it fits in there when the box looks so small but it does.


Doesn't get much more compact than this.


Rear view


After much discussion on what to do with mounting the fuel system Mitch came up with this two piece box.


The whole thing uses the factory hole for the fuel tank. The fuel filter and ethanol sensor will be mounted to the inside of the box when we have a better idea on exactly how best to mount them considering lines.


Then the whole thing will be bolted together with foam seals to keep it separate from the cab.


Intake pipe and the hot pipe completed now also.


Tight clearance to the hot pipe maybe a 5mm gap which should be enough.



Throttle cable tab welded directly onto the plenum. Which also shows the VVL solenoids mounted on top of the rail out of the way as much as possible.


The most minimal use of space we could come up with. Wondering when someone else will make a tiny aftermarket unit which does the same job.



More soon!

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Style

I love seeing updates on this build! Do you happen to have any pictures showing whats going on inside that swirl pot? Also how is air getting to that air box?

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scottie

This thread.................... makes my pants tighter.

Jissan

Immaculate build. I'm amazed every time updates are posted.

Makes me want to catch back up on my build... Nah. I'll just read this one again!

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ka-titties

such high level of fabrication skill and cleanliness. pure excellence!

i want you to update your build!