s13 - Turbo LS build

[91 240]

I’ve been been a member here for a while and have made enough progress to justify starting a build thread. It's taken a while to get to this point, but married life, a 6 month old, and going back to school for a 2nd degree really cuts down on time to work on the car.

Just a little background, I bought this car after graduating high school in 1997. In 1999, I swapped my first SR and enjoyed that for several years. But, during this time, I ended up going through several motors and 4 different turbo setups, enough was enough.

Here’s a bit of the build list:
2001 LQ4 6.0L
317 heads with mild port polish
Patriot dual valve springs
Callies Compstar H beam rods
Wiseco pistons (4.030")
Brute Speed Blower cam (232/240 duration and .595/608 lift)
Masterpower T76 Q trim turbo
JGS 40mm wastegate
JGS 50mm BOV
And much more

This is the car. I want to start off by apologizing for the picture quality. Lighting in my garage sucks and I don’t have a real steady hand apparently.
http://i18.photobucket.com/albums/b148/avery240sx/P2100015.jpg

And the previous setup. T67 fully built SR
http://i18.photobucket.com/albums/b148/avery240sx/P2100018.jpg

Here’s the motor when I picked it up. Dirty, but I’m tearing down for a build anyway.
http://i18.photobucket.com/albums/b148/avery240sx/P8220114.jpg

Here’s the test fit. I was going to try and use the truck manifolds, but I just didn’t like the clearance issues I was going to have.
http://i18.photobucket.com/albums/b148/avery240sx/carprogress015.jpg

So I decided to build my own headers. While waiting for piping and flanges to show up I focused on a few other things. I cut out the hatch floor area and made a new flat floor to make room for a new 16 gallon fuel cell. I also added a polished fuel door for access to fill the cell.
http://i18.photobucket.com/albums/b148/avery240sx/P4170136.jpg
http://i18.photobucket.com/albums/b148/avery240sx/PC050285.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P1010291.jpg



All the piping and flanges finally showed and it was time for me to start working on the headers, crossover, downpipe and exhaust.
Passenger header:
http://i18.photobucket.com/albums/b148/avery240sx/P1300308.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P1300311.jpg

Driver header:
http://i18.photobucket.com/albums/b148/avery240sx/manifold013.jpg
http://i18.photobucket.com/albums/b148/avery240sx/manifold011.jpg

Crossover:
http://i18.photobucket.com/albums/b148/avery240sx/P4170326.jpg

Wastegate placement and the beginning of the downpipe:
http://i18.photobucket.com/albums/b148/avery240sx/P4170344.jpg

Then it was on to the exhaust, all 3” except for where it splits to a homemade 2.5” y pipe that mates to the rear half of my Greddy DD exhaust. I really love the look and clearance of this catback so I wanted to make sure I could still use it.
http://i18.photobucket.com/albums/b148/avery240sx/P4170337.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P4170338.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P4170339.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P4170340.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P4170341.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P4170332.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P7100329.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P7100330.jpg

I can’t weld aluminum yet, so I had a friend take care of the intercooler piping along with the BOV flange and AIT bung. I also mocked up the air filter. It tucks up right behind the vent below the turn signal.

http://i18.photobucket.com/albums/b148/avery240sx/P7100328.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P7100325.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P7100324.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P7100326.jpg

[91 240]

I made a couple mounts for a powersteering cooler behind the intercooler.

http://i18.photobucket.com/albums/b148/avery240sx/P9240350.jpg

I was able to finish a 6 point rollbar out of an S&W Racecars 8 point setup (no pics of the door bars).
http://i18.photobucket.com/albums/b148/avery240sx/PA010360.jpg

http://i18.photobucket.com/albums/b148/avery240sx/PA010363.jpg

http://i18.photobucket.com/albums/b148/avery240sx/PA010364.jpg

I made a dump/down turn for my cutout. I'm still waiting on my E cut out.
http://i18.photobucket.com/albums/b148/avery240sx/PA010365.jpg

I also got the majority of my fuel system. Professional Products rails, Bosch 044 pump, Siemens 60lb injectors, Trick Flow 10 and 100 micron filters, Aeromotive 13101 FPR, -8 feed and -6 return.

http://i18.photobucket.com/albums/b148/avery240sx/P9240348.jpg

FPR mounted on the firewall, and notched the pinch weld at the firewall.
http://i18.photobucket.com/albums/b148/avery240sx/PA010355.jpg

http://i18.photobucket.com/albums/b148/avery240sx/PA010357.jpg

i primarily have the pump and pre-filter tucker up behind the passenger rear tire. I'm going to add/build a shield to help protect it.
http://i18.photobucket.com/albums/b148/avery240sx/PA010358.jpg

[91 240]

The battery must have exploded before i bought the car back in 1997, there was rust everywhere behind the passenger headlight. I cut the headlight panel and part of the core support out so i could sand blast the rust and weld everything back in. I cut out the front fender wells due to a shady shop's work cutting holes for intercooler piping and welded in new patch panels.

drivers side - still have to finish welding and grinding. it'll be easier to finish after i pull the motor.
http://i18.photobucket.com/albums/b148/avery240sx/PA160388.jpg
http://i18.photobucket.com/albums/b148/avery240sx/PA160391.jpg
http://i18.photobucket.com/albums/b148/avery240sx/PA160392.jpg

passenger side
http://i18.photobucket.com/albums/b148/avery240sx/P1150418.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P1220430.jpg

I also got an Fbody aluminum driveshaft that i had shorted 2" and replaced the u-joints. I also had to use a 1310 to Nissan differential flange to mount to my rear end. fits perfect with plenty of exhaust clearance.
http://i18.photobucket.com/albums/b148/avery240sx/P1150416.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P1150417.jpg

i pulled the motor and tranny from the car and assembled everything on the engine stand.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0363.jpg

i needed to add a few things that were damn near impossible to do with the motor in the car. first off was tapping the oil pan for the oil drain line. this looked like a good spot. clears everything inside and out.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0366.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0365.jpg

Next i wanted to add some support braces to the collectors....all that weight would eventually causing some cracking somewhere.
Drivers side
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0368.jpg

Pass side
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0367.jpg

these 2 braces helped out a ton, it's pretty solid now. I'm thinking of possibly adding another one on the crossover pipe and attaching it to the pass side head.

[91 240]

A few months ago i dropped my motor off at a machine shop to bore/hone the block .030 over, polish the crank, balance rotating assembly, deck block and heads, and do a 3 angle valve job. I picked everything up a couple weeks later with the plan to start building right away, but that didn't happen as i wanted to be sure everything was good to go. I bought a micrometer set and a dial bore gauge to blueprint the motor and get the correct bearings needed. It took me a while to find a place that had the needed 0.001" undersized bearings (both rods and mains) in stock. Finally got those in and the fun began.

Wiseco 4.030 pistons and Compstar H beam rods
http://i18.photobucket.com/albums/b148/avery240sx/P5120540.jpg

Installing the last rod/piston combo
http://i18.photobucket.com/albums/b148/avery240sx/P5130558.jpg

Installing BruteSpeed's Blower Cam.
http://i18.photobucket.com/albums/b148/avery240sx/P5130564.jpg

New LS2 Timing set
http://i18.photobucket.com/albums/b148/avery240sx/P5130566.jpg

I dont have any pics of the top end going together.

Since my last update I’ve finished assembling the motor, I’ve installed an ACT 6 puck clutch kit, new slave cylinder/lines and mated the T56. Before putting the motor and trans back in the car for the final time, I wanted to take time and clean up the engine. This started as a simple cleaning project that turned into stitch welding, shaving and re-painting the bay. All the time spent welding and grinding and adding body filler was brutal, way more than I had expected. Hopefully it will pay off in the long run. I don’t have any pics of the shaving process, but here are some pics of the first few coats of primer (iphone pics, sorry)

2 coats of Epoxy primer
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0582.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0583.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0584.jpg

Here it is after 2 coats of high build primer/surfacer
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0636.jpg

This weekend I’m hoping to get another coat or 2 of primer/surface laid down and block sand to get ready for the base coat.

I’ve been brainstorming on how to make my car different visually to help separate it from other 240’s and make it different. I’m not a fan of body kits or big wings. I’ve been intrigued with the hood scoops from the Toyota Tacoma, 4runner, and Rav4 and thought that might a way to spruce up the looks. I came across a hood from an early 90’s Toyota Celica GT All Trac locally on Craigslist for $75 so I jumped on it. This scoop is functional and could help with under hood temps, whereas the Tacoma/4runner/Rav4 are non-functional. I’m planning to cut the scoop out and weld it in to my stock hood. The lines and shape are very similar so hopefully after body filler it will all look good.
http://i18.photobucket.com/albums/b148/avery240sx/PC020041.jpg

the only other thing I’ve been able to do has been to get a new set of wheels/tires. Nothing special, but they are Mustang replica FR500 in a matte black finish (17x9 and 17x10.5) with Sumitomo HTRZ3’s 245/40 and 275/40.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0496.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P8040011.jpg
http://i18.photobucket.com/albums/b148/avery240sx/P8040010.jpg

Hopefully I’ll have more updates in the next few weeks.

[corby_baby]

aggie in austin? you live dangerously lol. builds look good, hope to see it one of these days.

[91 240]

aggie in austin? you live dangerously lol. builds look good, hope to see it one of these days.

damn straight! being in Austin the last couple of years as they've fallen apart is nothing short of AWESOME. Us Ags have needed something like this past year for so damn long, hopefully we can keep it going!

[91 240]

I got some work done over the last week or so, not as much as i would have liked but fate had something else in store for me this weekend.

last week i was able to wet sand the primer/surfacer smooth and get it ready for base/clear.

today i wanted to get 3 coats of base and 3 coats of clear, but i was able to get 2 full coats of base before my compressor decided to crap out on me.

Here are a couple pics of Summit Racing's single stage Jet Black base. Honestly, i think it turned out ok for my first time painting using a Devilbiss Starting line gun.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0032.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0034.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0036.jpg

Now on to what really ruined my day/night. I was just starting my 3rd coat of base when clanking from my compressor. I quickly shut it down and took off the plastic casing around the compressor motor.

Some how I was able to snap both connecting rods and shatter the cooling fan in my Craftsman 60 gal 6.5hp compressor. Not sure how, but now i get to track down a rebuild kit to hopefully try again next week.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0029.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0039.jpg

I'm calling this damn car Jack Stand Rocket, cause it's apparently never going to get off these jack stands.

[speedracer601]

Holy hell.

[Fable]

wow man sick build you got going on here with some awesome fabrication

[Kwolfe]

Craftsman products have lifetime warranties? Just get a new one?

[bc.]

wow, you are a psychopath.

[Oakville]

Holy fap that bay paint looks awesome.

[Nissansota240]

Nice build, looks like its coming along nice, are you making a shroud for around the intake filter? I had a similar setup on mine but any extreme amount of driving in the rain would allow it to suck in ridiculous amounts of water.

[BlewByYou]

Sweet build

[iStubz]

loving the wheel choice, different but sick.
and you crazy to boost an LS!

[slow92]

Wow looks good keep up the good work

[91 240]

I got some work done over the last 2 weeks. I got my replacement parts for my compressor and was able to finish painting the engine bay. 2 more coats of base followed by 3 coats of clear. Then i was able to get the motor and tranny back in the car for the final time, hopefully. I plan to get the rest of the front suspension and front wheels back on over the weekend. it'll be so nice to have it back on the ground. Now i can start the fun process of putting everything back together. i think i can see the light at the end of the tunnel....faintly.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0060_zps3eeb6ca6.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0062_zps4563dd61.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0065_zpsb58ed8d6.jpg

[revenn]

Looking awesome man keep it up!

[ryans523]

something ive always wanted to do, looking good!

[ShadowMan]

Damn, that's some really nice work on the headers, and the entire exhaust for that matter. I'll nkeep this in mind if I ever go with an LS. Awesome man.

[Royal_T]

Wow very sick build and you are not far from me at all.. Might have to check it out one day..

[91 240]

Well, I have another bit of an update. I don’t have too many pics to go with this but a good amount of work went on behind the scenes.

Here’s a little bit that went on since the last update.

- Dropped differential to replace seals
- changed differential flange on driveshaft from Nissan to Infiniti to mate to Q45 differential
- assembled complete rear end (axles, hubs, ISIS adjustable suspension links, Suspension Techniques sway bar, 300zx ebrake, 300zx rear calipers and all lines)
- fabbed DIY Power Brace
- assembled front suspension (Ground Control coilovers, Suspension Techniques sway bar, ISIS adjustable tension rods)
- assembled front brakes (300zx calipers with relocation brackets to accommodate 350z/G35 12.75” rotors)
- prepped/painted brake booster
- installed 300zx master cylinder and custom braided lines to replace stock hard lines in engine bay
- moved radiator overflow tank from passenger to driver side
- started assembling engine accessories – C5 alternator and power steering

300zx twin turbo calipers with 350z/G35 rotors
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0125_zpsca301397.jpg

DIY Power Brace
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0140_zps8bc381fc.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0141_zps2ee2879f.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0142_zps51f2fd58.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0148_zps5fd4ed02.jpg

300zx master cylinder with custom braided lines
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0149_zps8f39bf97.jpg

Engine bay slowing coming together
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0147_zps7942f7e4.jpg

I hoping to make some more progress over the weekend with more pics to come.

[240boi115]

holy hell this build is the shizzz!!!

[2muchboost]

Absolutely nuts my friend....I love it

[pigeon]

Paint looks great. Your running just the one 044 or do you also have one in tank?

[moco]

Did you have to do modified the transmission tunnel in any way?

[OrangeVirus1]

Can I ask why? I'd bet it's undrive-able in boost

[Slideways74]

You should get GTO accessory brackets to mount that ugly alternator down low where it can't be seen.

Looks good by the way.

[ForeignMuscle]

I think the gto alt bracket interferes on the s13 doesn't it?

[91 240]

I think the gto alt bracket interferes on the s13 doesn't it? i dont think it interferes, but i'm not 100% sure though

You should get GTO accessory brackets to mount that ugly alternator down low where it can't be seen.

Looks good by the way. i went with the C5 accessories for the extra 3/4" of pulley to radiator clearance. not to mention, putting the alternator down lower would interfere with my header collectors. Thanks!

Can I ask why? I'd bet it's undrive-able in boostno particular reason, other than i wanted to. it should still be driveable at around 600whp, maybe not until top of 3rd gear though

Did you have to do modified the transmission tunnel in any way? i did have to do a little bit of banging to clear the bell housing. not too much.

Paint looks great. Your running just the one 044 or do you also have one in tank? just that 1 external for now. should be plenty for my goals.....if not, i can add a 2nd one easily

Absolutely nuts my friend....I love it
Thanks!

holy hell this build is the shizzz!!!
Thanks!

Wow very sick build and you are not far from me at all.. Might have to check it out one day..
Where in Austin are you? i'm down south over by ABIA. I definitely want to check yours out too. i've been following you build on ls1tech. Has Russell been doing a lot of you work? I haven't talked to him in years....he's come a long damn way.

Damn, that's some really nice work on the headers, and the entire exhaust for that matter. I'll nkeep this in mind if I ever go with an LS. Awesome man.
Thanks man! just had to get a little creative

something ive always wanted to do, looking good!
Thanks

Looking awesome man keep it up!
Thanks!

Wow looks good keep up the good work
Thanks

loving the wheel choice, different but sick.
and you crazy to boost an LS!
Thanks. i've been in love with these wheels ever since the FR500 concept came out. I was originally going to go with the Black Chrome version, but when i found out about these, i decided to wait 8 months for the backorder to be filled.

Sweet build
Thanks

Nice build, looks like its coming along nice, are you making a shroud for around the intake filter? I had a similar setup on mine but any extreme amount of driving in the rain would allow it to suck in ridiculous amounts of water.
No shroud. i've changed the intake from what's pictured and tucks more into the bumper. plus, i dont plan to drive it all that much in the rain.

Holy fap that bay paint looks awesome.
Thanks! first time painter here. i think it came out pretty good. there are a couple of runs, but hey, it's just the bay! i'll pay a little more attention to the exterior when that time comes.

wow man sick build you got going on here with some awesome fabrication
i appreciate it!

wow, you are a psychopath.
my wife has said that to me before. :)

[91 240]

I got a little more done over the last week. Not huge progress, but taking care of a little odds and ends that i can mark off the "To Do" list.

First thing is something i did a couple months ago, but just got around to getting pics. I wanted to relocate the coils from the valve covers to give a cleaner looking appearance. I modified the brackets and mounted them to the inner frame rails.

Here is the original bracket. Everything with the silver marker was cut off and welded back to one piece.
http://i18.photobucket.com/albums/b148/avery240sx/photo-1_zpsdcd51503.jpg

Here's the completed bracket with coils mounted.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0176_zpsd06a85e8.jpg

Here are a couple shots of the brackets bolted to the frame rails. I welded a couple of bolts to the frame for the brackets to bolt to.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0099_zps17271541.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0069_zps99aa5943.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0150_zps90b90872.jpg

Next I added a ported throttle body to give a little bump in airflow and throttle response.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0173_zps21d2fa1b.jpg

Then I added a Hurst Billet Plus short throw shifter. I had to notch the shifter hole a bit to clear the shifter stop bolt.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0179_zps1f737199.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0181_zps3df7494a.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0180_zps6c2852de.jpg

I installed a Willwood 3/4" clutch master cylinder with custom mounting bracket and hooked up the clutch line. First pic is upside down, cant get the damn thing to save correctly. oh well
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0177_zps35b7376d.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0178_zps81649556.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0186_zps8b626757.jpg

Finally, I mounted the Aeromotive fuel pressure regulator with Autometer electric fuel pressure gauge sending unit.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0188_zpsdea0f446.jpg

The next week or so i'm going to focus on getting the interior cleaned and prepped for paint. A lot of sanding and masking still to come.

Stay tuned!

[Apex Eight]

Holy shit this build is badass. Subbed

[Smartone]

Nice fab skills! I live in Austin, well back and forth from Waco. I go to UT. I would love to come and check out the car next semester once I finish painting my 300zx. I plan on an LS swap later down the road in my Z, The VG just wont be enough after awhile...

[91 240]

Didn't get much done this weekend, but did get my manifolds back from the ceramic coating. I need to make/modify plug wires before i mount the manifolds for good.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0204-1_zps3edd309f.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0206-1_zps5dd2b5c8.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0205-1_zpsb00f6c35.jpg

[91 240]

Before I could install my freshly coated manifolds, i needed to get the plug wires in place. The relocation of the coils runs the plug wires under the manifolds towards the block.

I started off with a MSD 8.5" kit for the LS truck motors (32823), i bought these before i decided to do the coil relocation. I cut the wires to length, removing the straight boot and replaced them with 90* boots from MSD. I sleeved the wires with a set of Accel plug wire sleeves (170081) as they'd be pretty close.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0220_zpsb42ee723.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0220_zpsb42ee723.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0221_zpsb2d4fd8a.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0221_zpsb2d4fd8a.jpg.html)

Here are a couple of shots installed. I still have to modify the power steering lines so i'm leaving the driver's manifold off for now for better access.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0226_zps8c0c9bca.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0226_zps8c0c9bca.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0225_zpsca539731.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0225_zpsca539731.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0223_zps4a5ada30.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0223_zps4a5ada30.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0224_zps57d1b178.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0224_zps57d1b178.jpg.html)

[pigeon]

I can't wait to see the engine bay when its all finished. What are your hp goals?

[91 240]

Thanks! I can't wait either.

I'm shooting for 600 at 10-12 psi. Maybe more, but we'll when dyno time comes.

[05subysti]

damn this is BADASS, and local too! what turbo do you have again?

[91 240]

damn this is BADASS, and local too! what turbo do you have again?

Thanks! where in Austin are you?

Turbo is a Master Power 76mm Q-trim

[05subysti]

76mm turbo.. That is crazy lol youre gonna have so much traction issues haha :)

and i dont live in austin but i frequent there many times a week.

[pigeon]

Will this still use a stock MAF or will the HPtuners use a map sensor and inlet air temps like speed density?

[pigeon]

Never mind, just looked again and saw the IAT, so it would need a map sensor then..? Does that get wired into the stock harness? I'm confused as to how all that works.

[Pstl_pete]

Awesome build! Cant wait to see this put together.

[91 240]

Will this still use a stock MAF or will the HPtuners use a map sensor and inlet air temps like speed density?

No MAF.

Never mind, just looked again and saw the IAT, so it would need a map sensor then..? Does that get wired into the stock harness? I'm confused as to how all that works.

MAP sensors are stock on all LS models. There is a provision at the back of all LS manifolds for the sensor.

Awesome build! Cant wait to see this put together.

thanks man! i hope when i'm finished my car will look half way as nice as yours does! Love your project!!

[91 240]

Progress, Progress, Progress.

I got a little bit more done this week. I was finally able to mark one of the biggest "to do" items off my list. Now i can start putting the interior back together and move forward with wiring......YEAH WIRING!!!! :(

The big "to do" item was prepping and painting the interior. I painted about 75% of the interior yesterday....all that's left is the hatch area, but i have a quite bit of prep and rust clean up before i'm ready for paint. Hopefully i can tackle that here in the next few weeks. Masking off everything was fun. I painted the roll bar a Graphite Gray a while back so i had to mask that all off as well.....good fun. Stripping, sanding and cleaning took me quite a while.

Here are some pics of everything masked off before spraying.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0252_zps1f8ab248.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0252_zps1f8ab248.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0253_zpsba2f5d46.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0253_zpsba2f5d46.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0254_zps55b56779.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0254_zps55b56779.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0255_zpse8d782ae.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0255_zpse8d782ae.jpg.html)

Here is everything unmasked after 2 coats of epoxy primer. I'm leaving it in primer as it'll all be covered in carpet eventually.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0256_zps31ac7c76.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0256_zps31ac7c76.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0257_zpse65195f6.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0257_zpse65195f6.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0258_zps22b85025.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0258_zps22b85025.jpg.html)

Now the interior is ready for the new carpet i have waiting to go in. After that the wiring, dash, seats and interior panels can go in.

Next i moved back to the engine bay. I had to take care of the power steering lines before i could mount the driver's side manifold for good, as the lines run underneath the manifold and are very tough to get to from under the car. I assembled the lines (Russell Powerflex) and covered them with some heat wrap to help protect them from being so close to the manifold.

Here's a shot of the high pressure line coming from the pump to the rack.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0262_zps190a3934.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0262_zps190a3934.jpg.html)

Here's the low pressure line, not much to see as the majority of it runs under the coil bracket.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0263_zps7bea3d5a.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0263_zps7bea3d5a.jpg.html)

Here's the final shot of the driver's manifold, plug wires and steering lines.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0265_zps16972f3e.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0265_zps16972f3e.jpg.html)

From there i threw the crossover pipe back on. i need to make a brace for it to help support the turbo's weight, so that's another item that' s on my list. After that i can send it off for coating like the manifolds. Here are a couple of pics
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0266_zps620e0166.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0266_zps620e0166.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0267_zpsdbf54d3e.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0267_zpsdbf54d3e.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0268_zpsfe557c27.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0268_zpsfe557c27.jpg.html)

Next update I hope to have some of the interior back in and can continue to piece the engine bay back together.

[Michaelwinne]

Very nice man! And Hook 'em! ;) I was born and raised in Austin, and actually went to school at A&M, but not officially an Aggie. Can't turn my back on my roots!

[91 240]

i did a little more work over the weekend.

After painting the interior, next up was some new carpet. The new carpet is from stockinteriors.com that needed to be trimmed to fit the shifter, ebake handle, roll cage as well as for cutting holes for the seat bolts, center console, etc. I have a little left to do with the carpet, but should be able to start putting the interior pieces back in and running all the wiring inside the car.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0318_zps8a69158b.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0318_zps8a69158b.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0310_zps508ab135.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0310_zps508ab135.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0319_zps0cee1ca7.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0319_zps0cee1ca7.jpg.html)

After that i moved back to the engine bay. i got the last few pieces i needed painted/ceramic coated and put things back together. The turbo crossover, wastegate/dump, turbo housing and downpipe are all installed for good. I also started on some of the intercooler piping to connect the turbo to the throttle body. I'm leaving the compressor and CHRA off for the initial start and adding a block off plate in place, i dont want all the grinding debris/dust running through the exhaust wheel. Also, i dont want to run all the engine asssembly lube through the CHRA. All i really have left to do in the engine bay is wiring, fuel lines, adding all the fluids, bleeding the brakes/clutch, and that should be about it.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0308_zpsd2650ebd.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0308_zpsd2650ebd.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0309_zpsb14c8e59.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0309_zpsb14c8e59.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0315_zps87a92562.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0315_zps87a92562.jpg.html)

this is where i mounted my trusty Greddy Profec B boost controller
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0317_zpse00be70f.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0317_zpse00be70f.jpg.html)


I'm hoping to get a good bit of work done over the long weekend.

[Apex Eight]

So beast. Keep up the good work

[TheRealSy90]

I'm curious why your power goals are so low for a fully built motor? A 4.8 with rod bolts and everything else internally stock will make over 1000hp with enough boost, reliably as well.

[91 240]

I'm curious why your power goals are so low for a fully built motor? A 4.8 with rod bolts and everything else internally stock will make over 1000hp with enough boost, reliably as well.

600-700 is all i really want, which will be alot for this car. anything more will be a plus, but not very useable. Plus my current setup will running out of fuel at this level. a stock 4.8 wont make that power for long.

[05subysti]

such a fan of this car! moar updates :) i pmed you.

[Shanevasquez]

Damn man this is a awesome build! I wish I had this kind of money to put into mine. :( lol good work!

[silva.240]

The surely do go big in Texas! awesome job, mad props!

[91 240]

such a fan of this car! moar updates :) i pmed you.
Thanks man! Definitely more coming

Damn man this is a awesome build! I wish I had this kind of money to put into mine. :( lol good work!
Honestly, it hasn't been all that bad. I did have to part out everything from my SR swap to fund most of this. Plus it helps that i'm doing all the work. Labor could have been steep!!!

The surely do go big in Texas! awesome job, mad props! Thanks! I appreciate it!

So beast. Keep up the good work
Thank you!!

Very nice man! And Hook 'em! ;) I was born and raised in Austin, and actually went to school at A&M, but not officially an Aggie. Can't turn my back on my roots!
Boo!! haha. I grew up in Pflugerville and wanted to go to Texas, but went to visit friends at A&M for a game freshman year while i was at Blinn College, needless to say i transfer to A&M the following fall. Thanks!!

[S14kouki_10]

Great work, wanna weld up some stuff for me :p

[Mustache240]

soooo siiiccckkkkkk

[Smartone]

I would love to see this thing in person, I live in Austin. I have a 300ZX TT and also a shell waiting for a motor, probably an LS based motor. If you would let me check your car out sometime that would be awesome. Oh and unlike you I go to UT, but A&M was one of my other choices..

[7x13]

This thing is going to eat tires.

sub'd

[BiG MiKE86]

Insane build!!!

[ka-titties]

in for burnout vids

[h2v7]

yes please running vids and sound of that cutout

[91 240]

Great work, wanna weld up some stuff for me :p

Thanks! depending on what it is, I might be able to help you out.

soooo siiiccckkkkkk

Thanks man!

I would love to see this thing in person, I live in Austin. I have a 300ZX TT and also a shell waiting for a motor, probably an LS based motor. If you would let me check your car out sometime that would be awesome. Oh and unlike you I go to UT, but A&M was one of my other choices..

I don't have a problem with that at all. i'd like to get it a little more "presentable" beforehand though ;).

This thing is going to eat tires.

sub'd

I sure hope so!!!!

Insane build!!!

appreciate it man!

in for burnout vids

don't worry, they'll be coming.....eventually

yes please running vids and sound of that cutout

definitely!!

[91 240]

I have a little update, but nothing much to show picture-wise.

over the last few weeks/months, I've been focusing on wiring. I went through the entire LS1 harness and separated every wire and de-pinned both PCM connectors to remove unnecessary systems and to relocate the PCM in the car. At the same time, I relocated the engine bay fuse boxes and wiring. I'll post up fully completed pics when done.

I got to the point to try and start the car but was hit with another set back. Long story short, injectors are not being grounded by the PCM and therefore are not firing other than the first initial combustion cycle - here's a little vid IMG 0462 - YouTube (http://www.youtube.com/watch?v=QGsUoFxhbsM&feature=player_embedded) My initial thought was VATS was still enabled, but confirmed by 3 tuners it has been turned off.

After talking with several tuners and friends about the issue, I ordered HP Tuners to help diagnose the tune, to avoid having to ship my PCM off or wait for weeks at a time to schedule a time for a tuner to come by and take a look. It came in over the weekend and now i'm getting familiar with the software and I'm hoping to dive back into diagnosing my problem later this week.
http://i18.photobucket.com/albums/b148/avery240sx/hptuners_zps16f1d795.jpg

I'm hoping to have a better update next time around. Stay tuned

[91 240]

I've spent the last few weeks doubling checking my wiring and found 2 pinched wires (one to crank sensor and one to IAT). I've also updated my tune to a 2 bar OS and have added the correct injector data for my Siemens 60lb injectors.

I have a little bit more to do, but here are 2 new clips of it running before it dies.

http://www.youtube.com/watch?v=7CVB-...ature=youtu.be

http://www.youtube.com/watch?v=6qOPP...ature=youtu.be

[91 240]

It lives!!

I've done some more tweaking with the tune and now have it to a point where it runs consistently on it's own without dying.

RtZD16I-xNs

now I can focus on cleaning up all the wiring as everything is hooked up correctly and working. I can finish looming the engine harness and putting the dash harness back together.

Huge step for me and my motivation has picked up again. More progress to come over the long weekend.

Avery

[Michaelwinne]

Sounds awesome man! Hook 'em! :P

Sent from my SCH-I545 using Tapatalk 4 Beta

[Big Zee]

that is a beastly yet pure joy to hear even through a laptop.

Great work!! I look forward to more vids of it running :)

[Big Zee]

Also, love the fact you redid everything, engine, engine bay, interior, carpet. all the little things add up.

Kudos dude!

[Smartone]

So I need to come check this out for sure now. Recently I decided to part out my entire TT setup from my 300zx after it developed rod knock and now I am going with an LS based motor. Not sure yet on the exact motor, but a friend may be selling his LS3 and if not I will go boosted 5.3 or 6.0 (probably TT). I would love to come check it out this week or next to give myself some more incentive for the swap. My swap will be keeping my z32 trans as well as all the accessories by using customs brackets by LOJ Innovations.

Progress looks great!

[91 240]

I did a little more on my day off for Columbus Day.

after i got it started and running i developed a pretty big power steering leak. I had to pull most of the front of the motor apart to add a restrictor valve to the pump.

while i was at it, i pulled the manifolds off and wrapped them. with the manifolds generating a ton of heat and very close to my relocated coils, i figured it wasn't a bad idea. i wanted to do the crossover as well, but ran out. each manifold took 50ft of 1" wrap

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0582_zps6a008701.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0582_zps6a008701.jpg.html)

Next I put everything back together, drained the oil added the compressor and center housing, oil feed and drain lines, wastegate and vacuum lines. Engine bay is 98% done, all i have left to do looming a section of the engine harness and all should be good. just need to bleed the brakes and clutch and finish the interior.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0589_zps6fedf6a9.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0589_zps6fedf6a9.jpg.html)

[Charzilla]

dayymn so JDM ;)
Boosted LS tho....win in my book.

[91 240]

I have a little bit of an update guys.

after my last update, i had several other issues come up that slowed my progress.

1. after the p/s restrictor i added, i still had a pretty bad leak. this ended being a bad seal with Russell Powerflex p/s lines i made. the way i had the lines running put some stress on the fittings down at the rack. I added a couple inches to each line to take the stress off the lines and so far it's holding strong now.

2. next my clutch was not disengaging right and catching right off the floor. i had to drop the transmission to shim the slave cylinder out with a .078" shim. now the engagement is more in line with where it should be.

3. another item was my valve train noise. I originally went with a set of Thunder Racing 7.350" pushrods based off my measurements with a PR checker. Looking back, i was using a preload value of .060" from a stock LS1 lifter instead of the .080"-.100" for the LS7 lifters. I changed out a set of Speed Inc. 7.400" pushrods. i still have some noise, but it's better than before.

4. Lastly, i modified my exhaust some this weekend as part of it was hitting my rear diff.

I drove the car around the neighborhood yesterday to get a little feel for it, but didn't do too much with it. Coolant temps were getting a little high just from putting around, still need to troubleshoot this some more.

Here's a quick little vid of me backing it out of the garage and a little walk around. I still have a ways to go with wiring and getting the rest of the interior/exterior put back together.

3p6pclk9AzU

[BiG MiKE86]

=O man that's one sick build

[VQMaxFan]

May want to put in a comp trunion kit, stock rocker bearings are pretty noisy.

[91 240]

May want to put in a comp trunion kit, stock rocker bearings are pretty noisy.

Already have the trunion upgrade. Could be piston slap as well. Still have some diagnosing to do

[skateny115]

You may be able to shove a chasebays radiator up under your core support there and get your radiator a bit farther form your manifold piping. Possibly help with over heating problem.

[91 240]

You may be able to shove a chasebays radiator up under your core support there and get your radiator a bit farther form your manifold piping. Possibly help with over heating problem.

oddly enough, i've been contemplating that. or even another dual pass type radiator and adding a larger "low profile" puller.....current dual 12" pushers obviously aren't cutting it. i like the thought of CB's tucked radiator but, not liking the cost.....>$550 after slim fans, and remote filler neck and cap.

[2muchboost]

A couple of my buddies who are into drifting use the one i linked below. They drive an hr + then beat their cars then drive back home with no overheating issues. They say good fans, a good rad, and low temp thermo is the key. I have this rad and am looking to use Ford Taurus or Altima fans. I will be adding a low temp thermo as well, prob a 180 degree. This rad fits between the S14 rad location with no mods.

http://www.summitracing.com/parts/afc-80101ndp

[creatorvince]

Sick freaking build! Sounds and looks like a monster! Loving it

[valiants13]

That thing is beautiful!

[91 240]

Time for a few updates. Holidays took a lot of time from me and I dont have a lot to show for it pic-wise, but i have knocked out some big items.

The last time i posted on it, it was over heating pretty quickly just from idling or cruising around the neighborhood. Come to find out, a modification i did to the water pump to plug the heater core outlets actually blocked flow through the thermostat. Sooo, very little coolant was flowing through the motor, definitely not enough. I pulled the water pump and thermostat off and drilled a hole inside the pump to allow water to flow around the thermostat.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0696_zps41c5475e.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0696_zps41c5475e.jpg.html)

I drove the car around 5-10 miles, nothing too much, and things seemed to be working better. I only had 1 fan running and the temps never got above 205*, i'll keep playing with this more as I start putting more consistent miles on it.

I pretty much finished my engine bay wire tuck. I condensed and relocated the pass side fuse box under the dash (pics of this coming) and moved the driver's side relay/fuse box under the wheel well, basically the same location. cleaned up the bundle of wires i had zip-tied around the driver's headlight (if you noticed in the video) and ran the wiring along the lower radiator core support. Only have one pic of the box location.
http://i18.photobucket.com/albums/b148/avery240sx/P1260044_zps992044ff.jpg (http://s18.photobucket.com/user/avery240sx/media/P1260044_zps992044ff.jpg.html)

Then i was able to finally take care of something that i've been wanting to do for quite a while....i painted the hatch and quarter window areas with 2 coats of epoxy primer. Now i can put the quarter windows back on, get taillights mounted, relocate battery, mount the fuel door to the floor and then i can get the hatch back on. One step closer to being road worthy.
http://i18.photobucket.com/albums/b148/avery240sx/P1250042_zpsda234ce9.jpg (http://s18.photobucket.com/user/avery240sx/media/P1250042_zpsda234ce9.jpg.html)

I came across a deal that i couldn't pass up. I found a brand new set of CTS-V Brembos at a killer price. Rotors from a Mistubishi Evo 8/9 and Mazworx brackets.
http://i18.photobucket.com/albums/b148/avery240sx/photo1_zpsb616e791.jpg (http://s18.photobucket.com/user/avery240sx/media/photo1_zpsb616e791.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0707_zps0fb3b0b2.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0707_zps0fb3b0b2.jpg.html)

Pretty big size difference compared to the 30mm z32 calipers I had before(not my pic, I was working quick to get it done and didn't get a comparison pic)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0708_zps169c06cd.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0708_zps169c06cd.jpg.html)

Here's a wheel shot, i'll get better ones when I move it out of the garage again.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0735_zpsccd0f52b.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0735_zpsccd0f52b.jpg.html)

Finally, over the weekend i pulled the dash back out and have been working cleaning up all the wiring since everything works now, i need to make it a little more presentable. While i'm at it, i'm installing a new Viper alarm w/ remote start (Thanks Broadfield!).
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0748_zpsf0dbebef.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0748_zpsf0dbebef.jpg.html)

i'm hoping to finish all the dash wiring this weekend and start piecing the interior back for good.

[91 240]

A couple of my buddies who are into drifting use the one i linked below. They drive an hr + then beat their cars then drive back home with no overheating issues. They say good fans, a good rad, and low temp thermo is the key. I have this rad and am looking to use Ford Taurus or Altima fans. I will be adding a low temp thermo as well, prob a 180 degree. This rad fits between the S14 rad location with no mods.

http://www.summitracing.com/parts/afc-80101ndp

yeah, plugging the heater core ports doesn't allow for flow behind the stat, like putting a simple hose to loop the outlets. i'll test it a little more, if it doesn't work, I've got a custom tucked radiator in the plans using a Griffin dual pass.

Sick freaking build! Sounds and looks like a monster! Loving it
Thanks man! It felt good to drive it. first time in 5 years!!!

That thing is beautiful!
I appreciate it! it's not done yet, but getting close. Hopefully by the summer i'll have the exterior all body worked and painted.

[juvi22003]

sexy calipers

[Smartone]

Looks like good progress. I hope I can come out again soon. I almost have all my parts rounded up for my LS3 swap, need to figure out what I am going to do for headers.

[Konster]

Looking good.

[tougestyle]

really nice build !

[91 240]

well, I haven't had an update lately as I've been troubleshooting several things.

had a p/s leak in the rack, attempted a rebuild that failed epically, then finally settled on a reman'd rack.

Then I've been battling overheating issues. I caved and ditched my current setup to something else.

Old set up was a C&R single pass with dual 12" pusher fans and a 160* tstat.

Now i'm going with a Griffin 52801-x, dual 1.25" core, dual pass, a single zirgo 14" puller fan and an OEM 180* tstat.

i'm doing a custom tucked radiator setup to move the rad 3" away from the motor and turbo piping. this requires a little fab work that I haven't fully completed yet, but I have a few pics of where i'm at right now. I hope to have more progress over the next week or so.

pic of rad and new fan
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0822_zpsb704603d.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0822_zpsb704603d.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0823_zps92f3e879.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0823_zps92f3e879.jpg.html)

hole in the upper rad support for the rad filler neck
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0820_zps295eb4b4.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0820_zps295eb4b4.jpg.html)

notched about 3/8" from the lower rad support. i'll be welding this up to regain rigidity from notching
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0821_zps25e172fe.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0821_zps25e172fe.jpg.html)

front view of temp mounting
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0825_zps9a91f7d3.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0825_zps9a91f7d3.jpg.html)

engine side view of temp mounting
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0824_zpsa98742c9.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0824_zpsa98742c9.jpg.html)

new clearance I have to mount the 14" puller. I have right at 1" of space between the fan motor and exhaust. hopefully this will be enough
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0826_zps09af09a5.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0826_zps09af09a5.jpg.html)

I just need to figure out now to mount it to the car to be strong enough to support the weight.

Hopefully I'll have more updates in the next 2 weeks.

[Chaw wee]

Awesome build man, keep it up!

[supersayianjim]

Time for a few updates. Holidays took a lot of time from me and I dont have a lot to show for it pic-wise, but i have knocked out some big items.

The last time i posted on it, it was over heating pretty quickly just from idling or cruising around the neighborhood. Come to find out, a modification i did to the water pump to plug the heater core outlets actually blocked flow through the thermostat. Sooo, very little coolant was flowing through the motor, definitely not enough. I pulled the water pump and thermostat off and drilled a hole inside the pump to allow water to flow around the thermostat.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0696_zps41c5475e.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0696_zps41c5475e.jpg.html)

I drove the car around 5-10 miles, nothing too much, and things seemed to be working better. I only had 1 fan running and the temps never got above 205*, i'll keep playing with this more as I start putting more consistent miles on it.

I pretty much finished my engine bay wire tuck. I condensed and relocated the pass side fuse box under the dash (pics of this coming) and moved the driver's side relay/fuse box under the wheel well, basically the same location. cleaned up the bundle of wires i had zip-tied around the driver's headlight (if you noticed in the video) and ran the wiring along the lower radiator core support. Only have one pic of the box location.
http://i18.photobucket.com/albums/b148/avery240sx/P1260044_zps992044ff.jpg (http://s18.photobucket.com/user/avery240sx/media/P1260044_zps992044ff.jpg.html)

Then i was able to finally take care of something that i've been wanting to do for quite a while....i painted the hatch and quarter window areas with 2 coats of epoxy primer. Now i can put the quarter windows back on, get taillights mounted, relocate battery, mount the fuel door to the floor and then i can get the hatch back on. One step closer to being road worthy.
http://i18.photobucket.com/albums/b148/avery240sx/P1250042_zpsda234ce9.jpg (http://s18.photobucket.com/user/avery240sx/media/P1250042_zpsda234ce9.jpg.html)

I came across a deal that i couldn't pass up. I found a brand new set of CTS-V Brembos at a killer price. Rotors from a Mistubishi Evo 8/9 and Mazworx brackets.
http://i18.photobucket.com/albums/b148/avery240sx/photo1_zpsb616e791.jpg (http://s18.photobucket.com/user/avery240sx/media/photo1_zpsb616e791.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0707_zps0fb3b0b2.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0707_zps0fb3b0b2.jpg.html)

Pretty big size difference compared to the 30mm z32 calipers I had before(not my pic, I was working quick to get it done and didn't get a comparison pic)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0708_zps169c06cd.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0708_zps169c06cd.jpg.html)

Here's a wheel shot, i'll get better ones when I move it out of the garage again.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0735_zpsccd0f52b.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0735_zpsccd0f52b.jpg.html)

Finally, over the weekend i pulled the dash back out and have been working cleaning up all the wiring since everything works now, i need to make it a little more presentable. While i'm at it, i'm installing a new Viper alarm w/ remote start (Thanks Broadfield!).
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0748_zpsf0dbebef.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0748_zpsf0dbebef.jpg.html)

i'm hoping to finish all the dash wiring this weekend and start piecing the interior back for good.




I have this alarm system, very pleased!!

[2muchboost]

Nice job on the tucked rad...really digging it. Let me know what you think about the CTSV brake setup. Been tossing around the idea of swapping out the fronts as well for the same setup.

[91 240]

I took the day off of from work yesterday to get a little bit of work done, as time on the weekends just doesn't exist anymore.

I worked more on my tucked radiator setup.

First I boxed in the lower rad support. prep and paint should happen over the weekend.....maybe
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0832_zps60f60b54.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0832_zps60f60b54.jpg.html)

Then I welded on 1" pieces of 3/8" alum rod to each side of the radiator to mimic the OEM upper mounts and reused the stock rubber isolators. I made a couple of brackets that still need to be trimmed and them bolted to the core support to fully mount the radiator.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0830_zps0e076543.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0830_zps0e076543.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0831_zpsa3f60d8d.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0831_zpsa3f60d8d.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0833_zps40de2808.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0833_zps40de2808.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0834_zps84b011a0.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0834_zps84b011a0.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0836_zpsce4543f7.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0836_zpsce4543f7.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/b40c0dc5-b414-4265-a849-58c05c182bc0_zps0fedaf05.jpg (http://s18.photobucket.com/user/avery240sx/media/b40c0dc5-b414-4265-a849-58c05c182bc0_zps0fedaf05.jpg.html)

[Smartone]

This made me highly consider tucking the radiator on the Z32. I really want to do it, but it may be done later down the road. Likely when I get another place with a garage and/or as a winter project. Nice update!

[91 240]

Slow, Slow progress with the tucked radiator, but coming down the how stretch....hopefully.

Big thing to do was to clean up the upper core support and repaint as drilling a 3.5" hole and notching for the upper outlet did some damage to my nice(ish) paint.

prepped and sanded with 340 grit
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0840_zps18ccc62a.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0840_zps18ccc62a.jpg.html)

2 coats of 2k primer/surfacer
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0841_zpsade09bed.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0841_zpsade09bed.jpg.html)

Prepped and wet sanded with 800 grit
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0868_zpse627ae54.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0868_zpse627ae54.jpg.html)

Finally, 2 coats of single stage jet black base
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0870_zps1bbcc21c.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0870_zps1bbcc21c.jpg.html)

Tonight and hopefully later this week I strip all of the masking off and starting mounting everything back on to the car.

Big plans for this weekend are to bleed the coolant and test to make sure the new setup is working properly. Then hopefully, i'll be able to put some miles on it to get an alignment done.

[Theezy]

too sick! i don't think my jaw could drop any lower. i need to see more! also very jealous of your fab skills

[91 240]

I got some work done over the weekend and completed my tucked radiator setup, well, for the time being.

I got it all buttoned up and decided to take it for a test drive to get an alignment. it did pretty good for the most part until I got stuck in traffic or at lights, then it started to warm up again. once I got moving it cooled back down some but still a little warm for my liking. The upper hose is very close to the exhaust, i some heat wrap on the way for that. I took it back apart again and am working on building a custom fan shroud as well as adding a surge tank to aid in bleeding coolant. More details on this over the weekend.

On to some pics

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0877_zpse0ad16a9.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0877_zpse0ad16a9.jpg.html)



http://i18.photobucket.com/albums/b148/avery240sx/IMG_0878_zpsd84e199c.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0878_zpsd84e199c.jpg.html)



http://i18.photobucket.com/albums/b148/avery240sx/IMG_0874_zps93b4b380.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0874_zps93b4b380.jpg.html)



http://i18.photobucket.com/albums/b148/avery240sx/IMG_0876_zps41311fbc.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0876_zps41311fbc.jpg.html)



http://i18.photobucket.com/albums/b148/avery240sx/IMG_0879_zpsd5bd399b.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0879_zpsd5bd399b.jpg.html)



http://i18.photobucket.com/albums/b148/avery240sx/IMG_0880_zps9103302d.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0880_zps9103302d.jpg.html)

[240s3x]

.....dope!

[91 240]

Alignment is done, and we're on the road!

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0929_zpsbcd13b3a.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0929_zpsbcd13b3a.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0928_zps33cb5f69.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0928_zps33cb5f69.jpg.html)

I've added an external surge tank from Keyser Manufacturing to help with the cooling issues I've been having. Huge help but still have some kinks to work out.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0925_zpsd8fa4a91.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0925_zpsd8fa4a91.jpg.html)

I've also finally mounted my Saikou Michi dual catch can and routed all lines.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0926_zps7167bd79.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0926_zps7167bd79.jpg.html)

Here's the final bay setup. I don't plan of changing anything else at the moment.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0927_zps87eaec3c.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0927_zps87eaec3c.jpg.html)

Here are some general shots of the car as it sits now. It's about 98% complete right now, hatch wiring, couple of interior panels, glove box, headliner, etc.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_0932_zps160a09fd.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0932_zps160a09fd.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0930_zpsa01d82a0.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0930_zpsa01d82a0.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0933_zpsc7a643b1.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0933_zpsc7a643b1.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0934_zpsefac62c2.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0934_zpsefac62c2.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_0935_zpsa3ee6e34.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_0935_zpsa3ee6e34.jpg.html)

Finally, I've got an in car vid of the last few miles of my way back home from getting the alignment. Feels damn good to drive it again.

uAELJjAqTNQ

[91 240]

Wow, I haven't updated this thread in a while. I've been battling cooling issues lately.

I decided to go ahead and ditch my current 14" Zirgo (2300cfm) fan and custom shroud setup for a Taurus fan with Volvo relay set up.

First, I had to trim the fan shroud as it was a little wide for my radiator. I trimmed and fiberglassed the section removed to seal in the area trimmed off.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1147_zps0d432844.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1146_zps0b687e5e.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1159_zpsb64ae6d5.jpg
http://i18.photobucket.com/albums/b148/avery240sx/a710deed-ef77-49de-88d1-6c3892d7149e_zps677ef873.jpg

Next, I had to move the radiator forward another 3" and down 1". Ending up having to cut out the entire upper core support. Cutting out the core support, I also lost my hood latch. I have a set of Aerocatch pins that i'll be adding. Also had to cut/patch the filler neck to clear the hood

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1149_zpscaa6d098.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1173_zps94b021e9.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1175_zpsb2f0b7c3.jpg
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1174_zpsfbb66d5c.jpg

Finally, I had to relocate my p/s cooler under the driver side wheel well.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1176_zps62a0dc0d.jpg

First impressions are AWESOME! right now I have the fans set to come on at 200* and off at 190*. On low speed, it takes about 20 seconds to drop temps 13* at idle. Bled the coolant for 40 minutes and never peaked over 201*.

Driving tests with no hood or front bumper were also very solid. 80-85* outside, 20 mile stop and go trip showed the same results....202* max while sitting at a light and quickly dropped to 190* with the fan. Cruising temps stayed right around 187-190*. I know this is not an accurate test as the hood and bumper will impact airflow, but it's a hell of a start.

Finally, I've started a little bit of work on my hood to incorporate a GT500 hood vent. Right now it's just a few pilot holes and measuring before I cut out the necessary section. Here's crappy pic of the vent just lying on the hood in the general area.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_3484_zps2c402424.jpeg

I've also added a MGW shifter to replace the Hurst Billet. 3rd gear would hit the shifter trim and kick out of gear occasionally. Offset of the MGW is spot on. Shifting is awesome with this!! Reverse can be a little touch sometimes, but manageable.

http://i18.photobucket.com/albums/b148/avery240sx/photo_zps333f3481.jpg

[91 240]

yes please running vids and sound of that cutout

it's not a great vid, but definitely sounds good. i'll try to get a vid with the cutout open while driving.

9VUDfichwso

[U mirin]

it's not a great vid, but definitely sounds good. i'll try to get a vid with the cutout open while driving.

9VUDfichwso

*drooool*:eek2:<--- that's normal right? Sick build man. So much inspiration in this build. And all of them honestly. I really would love to learn how to do fabrication. Props to you!

[91 240]

I haven't had much of an update lately, but have a bit to show for work that's been done over the last couple of months.

This is still all cooling related.

Back in October i took it to meet a buddy who's a freelance tuner. This drive was without the hood but put the bumper back on. it didn't take too long to find out that the airflow to the radiator with the bumper on was lacking. 20 miles into the 50 mile trip, temps started climbing. low speed with the Taurus fan wasn't keeping up so i had to run the fan on high just to get the temps to drop back in the 200* range. However, i made it without any issues. We were able to get some good off boost tuning done. Car felt pretty damn good while doing so. Here's a shot with his C7 Vette, such a smooth driving car that's making 490whp.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1182_zpscc19552c.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1182_zpscc19552c.jpg.html)

On the way home is where things started getting interesting.

running the fan on high the entire time eventually took it's toll. Alternator fuse ended up blowing and voltage dropped to 10v. Pulled over and called a tow truck to come get me and to continue brainstorming.

Once home, i planned to focus on 2 things:
1. ducting between intercooler and radiator
2. add some bumper vents to get air directly to the radiator

I recently picked up a new TIG welder. nothing special, but should do everything i will need for a long time. AHP AlphaTig 200
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1235_zpse5ec9d93.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1235_zpse5ec9d93.jpg.html)

I welded up some ducts to force all air going through the IC directly to the radiator. I used some .060" alum sheet for my ducting. First time welding alum so go easy on the criticism

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1248_zpsa5178c57.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1248_zpsa5178c57.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1253_zpsc5b4b67e.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1253_zpsc5b4b67e.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1252_zps5e0d4408.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1252_zps5e0d4408.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1250_zps75d9cd17.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1250_zps75d9cd17.jpg.html)

This helped a lot on it's own, but want to do some bumper work as well.

I got a spare bumper that i used to cut up for testing. I added a duct in the bumper that was right above the intercooler that fed directly to the top 6" of the radiator. I had to cut up the hood to fit the relocated radiator, which included cutting the stock latch. I went ahead and added a set of AeroCatch hood latches.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1281_zpsca794dfa.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1281_zpsca794dfa.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1282_zpse966abc2.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1282_zpse966abc2.jpg.html)

I took it for a drive last week, 100+ miles and the temps never got above 185*. Felt pretty damn good to drive without fear of overheating.

Now i'm planning to rack up some miles and hopefully get it tuned in the next couple of months.

[2muchboost]

Slap on forehead......I didn't even think to offer that recommendation. Almost every LS 240 around here has some ducting to help focus the air over the Rad. I was so excited about your build it didn't cross my mind. Since you have the fab skills look into making a cooling panel for even more airflow over the Rad.

Glad you got the cooling figured out.

[Choppz]

Wow awesome build and skills

[benz88]

Looks sick! Im just in the process of starting a Turbo LM7 S13 build.

[91 240]

Slap on forehead......I didn't even think to offer that recommendation. Almost every LS 240 around here has some ducting to help focus the air over the Rad. I was so excited about your build it didn't cross my mind. Since you have the fab skills look into making a cooling panel for even more airflow over the Rad.

Glad you got the cooling figured out.

No worries man. it's the last thing I wanted to do as I wanted to keep it as stock looking as possible. Oh well, as long as it runs safely, i'm ok with it

Wow awesome build and skills

Looks sick! Im just in the process of starting a Turbo LM7 S13 build.

Thanks guys!

[jons14]

Wow awesome build!
Would love to see some videos of this thing doing some good pulls or burnouts haha!

[nick Ritter]

gonna need a wider tire out back !

[91 240]

I finally got my car tuned today. Not quite what I was hoping for, but based on the boost levels i'm definitely happy.

Final numbers:

608whp and 526wtrq at 8psi

we were limited to boost based on my EBC not responding and relying on waste gate spring pressue ~ 7-8psi.

Fuel was only hitting 70% duty cycle so there was definitely more left in it.

12-15psi could have put us into 650+whp. oh well, i'll definitely be back for more.

right now, it's still a chore to handle this much power in such a little/light car.

Here are some vids from the day.

568whp at 7psi

82UO-SQ1IdE

590whp at 7psi - fedex guy wanted to take a peek

1AJ6Ohpt8lo

608whp at 8psi

d-S2vqHSk_c

[Smartone]

Awesome! My Z should be back up tomorrow after I redo my AN lines. I'll hit you up sometime this weekend so we can meetup.

Great power! My 500 rwhp feels great I'm sure yours is even more fun!

[91 240]

Here's my dyno graph from the final run

http://i18.photobucket.com/albums/b148/avery240sx/dyno_zpseejza7jh.png (http://s18.photobucket.com/user/avery240sx/media/dyno_zpseejza7jh.png.html)

[motoman159]

God this is good. How's it hook up with those tires?

[blasian]

Nice numbers

[91 240]

God this is good. How's it hook up with those tires?

Thanks! Hook up needs more work. Non-existent until the top of 4th.

Nice numbers

Thanks man!

[Hoonigan19]

sik build man, love the fabrication skills

[91 240]

Man, i haven't updated this thread in quite a while.

after my last post, i've changed quite a bit on the car. Swapped in a set of LS3 heads and intake. had a custom spec'd cam made did some street tuning. Drove for a few months pretty solidly but didn't get it dyno'd again.

this was a couple months back. since then i was still troubleshooting the cooling issues during the summer here in Texas. I cut up my stock hood to mimic a vent as an experiment. Turns out it worked pretty well. With there not being many vented hoods for the 240 that i liked, i ordered one from Japan. Took over a month to be made and shipped, but was worth it.

I got an Origin Aero Type 1 FRP hood. I have a few mods to make to clear the motor, but outside of that, i just need to prep and paint it. I've got some Summit Satin Hot Rod Black (matte black) to paint the hood in the short term, but long term the entire car.....maybe later this summer, hopefully.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1879_zpsichu1c42.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1879_zpsichu1c42.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1880_zpsmcvqe9hz.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1880_zpsmcvqe9hz.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1901_zps2mi4uxbd.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1901_zps2mi4uxbd.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1902_zps5asrt5k9.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1902_zps5asrt5k9.jpg.html)

I had a set of AeroCatch hood pins in my stock hood, but i dont want to cut up this FRP hood, so i've decided to revert back to the stock hood latch setup. this required getting a new upper radiator core support as it has the hood latch mount. I got a nose cut section from a friend for this. I cut the upper support out and the have corresponding headlight support brackets. I'm in the process of cutting out what i currently have on the car now. More on the deconstruction of the car to come.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_1899_zpsgdamd0tx.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1899_zpsgdamd0tx.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1900_zpshtcxdsgy.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1900_zpshtcxdsgy.jpg.html)

Moving back to the stock core support and hood latch, means i have to move the radiator back about 5". The current Taurus fan is too deep, so i'm working on a new shroud/fan set up and also leads to this next update. My current turbo crossover runs right infront of the waterpump pulley which is pretty tight for the radiator and fan.

I've been planning a new turbo setup for months and now have to do it to fit everything. I got a recent shipment from Ace Race Parts, all stainless that will be fully tigged and back purged. More pics of the fab work coming. For now, here's some good polished stainless piping goodness.

1/2" manifold, turbo and wastegate flanges
1 5/8" 304l 16ga tubing for wastegate
1 3/4" 304l 16ga tubing for manifolds and going to make custom collectors
2.5" 304l 16ga tubing for crossover
turbo blanket
2.5" stainless vbands
flat and round bar for bracing
trying to decide if i want 3" or 3.5" for the downpipe. This should keep me busy for a while

http://i18.photobucket.com/albums/b148/avery240sx/IMG_1903_zpsqyfpd2rf.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_1903_zpsqyfpd2rf.jpg.html)

More to come.....

[blasian]

Keep up with the updates, goin to be exciting to watch.

[2muchboost]

Nice progress dude. Lmk of you need an extra hand. I am officially down in ATX and have some free time when not traveling around for work.

[Jorgs_7]

This is fantastic, just went through the whole thread.

Were those headers done with a MIG? 110v?

That air compressor thing had me lol'in, I couldn't believe it.

Kudos to you sir! Love it

Do you have an idea on the total time duration and dollar spent on this project?

[91 240]

Keep up with the updates, goin to be exciting to watch. Thanks. if only I had more time

Nice progress dude. Lmk of you need an extra hand. I am officially down in ATX and have some free time when not traveling around for work. Thanks Herb! sucks we haven't been able to meet up since you've moved down here. I'd definitely take you up on that offer, I just never know when I get to work on it. it's usually last minute or LATE at night. You still have the 631 number?

This is fantastic, just went through the whole thread.

Were those headers done with a MIG? 110v?

That air compressor thing had me lol'in, I couldn't believe it.

Kudos to you sir! Love it

Do you have an idea on the total time duration and dollar spent on this project?

Thanks man, I appreciate it. The original and current headers were mig'd with a Miller 140 autoset, running off 110/115v. There were a Jeg's universal header kit, 1 5/8 aluminized steel.

Air compressor scared the shit out of me when it happened and pissed me off as I was in the f'n middle of my final base coat pass. no I look back and laugh.

I don't really know on the number of hours, but I might have to guess over 500 since starting the swap. i haven't tallied my receipts in a while, but at one point it was close to $15k for parts, tools, materials, etc. probably much more than that now. I'd guess about $30-40k if a shop would have done the work.

[2muchboost]

Yes sir. If I am not traveling or seeing clients I am working from home so feel free to shoot me a text any time bud.

[Malik]

looking good thanks for sharing.

[91 240]

I've been out and away from the car for the past few months, but finally had some time to do some work over the weekend.

I started working on my new manifold set up. all 1.75" 304SS. I was able to get 3 of the 4 driver's side manifold cut, fit and tacked in place. I hope to finish the last runner next weekend and get it all tigged up shortly after that.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2151_zpsntos3qqg.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2151_zpsntos3qqg.jpg.html)

Also, i recently got one of my last shipment of materials in for the exhaust. All 304SS as well. Stepping up to 3.5" from the 3" i had on the last setup. I'm going to make a clone of my Trust DD catback, which was 3" to dual 2.5" that opened up to dual 3.5" tips. This time, i'm going 3.5" to dual 3" to dual 3.5" tips.

Here's what i've got:
7' of 3.5" straight polished (4' not pictured, on back order)
5' of 3.5" oval tubing
(4) 3" 90* bends
4' of 3" straight tubing
Vibrant 3.5" race muffler
3.5" stainless flex section
2.5" stainless flex section
(3) 3.5" stainless vband kits
(2) 3" > 3.5" transitions

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2149_zpsvmekfxx7.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2149_zpsvmekfxx7.jpg.html)

hopefully more to come in the next few weeks

[91 240]

Man, i have not updated this in a while

I have been able to make some progress just recently on the fabrication of new manifolds. Right now i only have the driver side in the works. I've changed the layout from one of my previous posts. Runners are fully welded, just need to do the collectors and then weld the runners to the head flange. FIrst big SS TIG project, so far so good.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2635_zpsqdvtbs8k.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2635_zpsqdvtbs8k.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2634_zps6n2o7frt.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2634_zps6n2o7frt.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2751_zpst8c6letl.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2751_zpst8c6letl.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2752_zpsphncziwa.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2752_zpsphncziwa.jpg.html)

while i continue to work on the new manifolds i need to address cooling issues i've been having.

I posted a fiberglass vented hood last year but had several modifications that needed to be done in order for it work.

with my previous setup, mainly the Taurus fan, i had to cut out my radiator core support and move the radiator forward 4+ inches. This time around, i wanted the support back in place so it didn't look so hacked. I welded in the replacement core support and worked on making new mounts for the radiator to tuck up under the support.

To do this, i started by making a alum shroud and used a Volvo 850 e-fan, pretty much the same motor as the Taurus fan but 3" thinner which allowed me to move it back towards the engine.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_2454_zpsaggedmnt.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2454_zpsaggedmnt.jpg.html)

made some new mounts as well. lower mounts not pictured.
http://i18.photobucket.com/albums/b148/avery240sx/IMG_2457_zpsebdjdmtd.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2457_zpsebdjdmtd.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_2458_zps9msiqcut.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2458_zps9msiqcut.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_2459_zpsjbawexxi.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2459_zpsjbawexxi.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_2461_zpswii7wdhe.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2461_zpswii7wdhe.jpg.html)
http://i18.photobucket.com/albums/b148/avery240sx/IMG_2460_zps453t520p.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2460_zps453t520p.jpg.html)

With the fan mounted, wanted to make some coolant hard pipes to get rid of cut up radiator hoses. silicon couplers and 1.75" aluminum tubing.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2455_zps9rhpnl4i.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2455_zps9rhpnl4i.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2512_zpsfi8kgtxl.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2512_zpsfi8kgtxl.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2510_zpstu0dq09s.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2510_zpstu0dq09s.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2464_zpsklfu12s7.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2464_zpsklfu12s7.jpg.html)

After that, i prepped the engine bay to paint the newly installed core support and welded a few bolt holes shut

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2937_zps3ntdxa9t.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2937_zps3ntdxa9t.jpg.html)

Along with battling the high coolant temps, i was consistently having 250* oil temps, 40* over coolant temps just from daily driving. I decided to add an oil cooler setup and a new power steering cooler.

B&M 23 row super cooler 70273
Derale 180* oil thermostat
Derale powersteering cooler
Mishimoto oil cooler adapter for the Pontiac GTO oil pan (Improved Racing didn't have the GTO adapter available any longer)
assortment of Jegs -10an fittings and nylon braided line

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2936_zpse6lf8q2f.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2936_zpse6lf8q2f.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2938_zpsvodhadkj.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2938_zpsvodhadkj.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_2939_zpsj13zkqgl.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_2939_zpsj13zkqgl.jpg.html)

mounted the thermostat on the fender well side of the driver frame rail. Plenty of wheel/tire clearance, plus will be protected when the fender liner goes back in.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_3012_zps6apqo8zs.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_3012_zps6apqo8zs.jpg.html)

then i fabbed up a bracket to mount the cooler. cut a piece of 1.5 x 1.5 x .125 aluminum angle. going to brace a little more though. Mounting it right below the driver headlight behind the lower vent below the turn signal on the 91-94 bumper.

http://i18.photobucket.com/albums/b148/avery240sx/IMG_3013_zpsusvww6se.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_3013_zpsusvww6se.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_3015_zpstohgmikk.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_3015_zpstohgmikk.jpg.html)

http://i18.photobucket.com/albums/b148/avery240sx/IMG_3018_zpso6cirbh9.jpg (http://s18.photobucket.com/user/avery240sx/media/IMG_3018_zpso6cirbh9.jpg.html)

I'm currently working on the lines right now, but need a few extra fittings and hope to have this buttoned up in the next couple weeks.

More to come!

[Smartone]

I would come check out the updates you have made but I moved across the country.

What welder are you using? Looking to pick one up myself that I can use in my garage.

[ka-titties]

good work man.

are you using a gas lens on your TIG for those stainless welds? if not, I highly suggest one. check out the Furick cup ;)

[91 240]

I would come check out the updates you have made but I moved across the country.

What welder are you using? Looking to pick one up myself that I can use in my garage.

Hey man, where did you end up? i'm guessing you moved this summer? after graduation?

good work man.

are you using a gas lens on your TIG for those stainless welds? if not, I highly suggest one. check out the Furick cup ;)

Thanks man! yeah i have an assortment of gas lenses. i know my stainless welds are a little hot, just haven't been able to find the sweet spot yet. currently i'm at 35-40 amps and 25cfh with .035 308 filler rod on those welds. by the time i finish the other manifold, crossover, and exhaust, i might have it down.....

[Smartone]

Graduated and now I am now in Seattle! Building another 300ZX LS car but this time building it for Road Race.

[91 240]

Damn I've been away for a while. I lot has happened since my last update. Moved from a house to an apartment and finally to our new house back in September.

I've actually done a lot lately, but i dont have too much to show for it. Some out of necessity and other self inflicted. Oh well

I'll start with more self inflicted first, as that's more fun to talk about.

Starting simple. I saw a shift knob I fell in love with years ago but found out it had been discontinued. I had asked if they could do a one off but they no longer had the prints for it, so I said what the hell I'll get it anyway. Turns out they sell blank shift pattern discs and I found a local engraving company to copy the pattern. It's a MGW Gripper knob to go with my MGW short shifter. Here's the original MGW piece
https://i.imgur.com/Is3It2I.jpg

Here's the new one with the piece i had made locally....pretty damn good!!!!
https://i.imgur.com/91VoqMn.jpg

Next i got a set of JDM 180sx Chuki side skirts. I've been eyeing these for a while but finally pulled the trigger when a friend decided to sell his set locally.
https://i.imgur.com/Z5eMHR1.jpg
Not a great pic.....
https://i.imgur.com/DXoBwzr.jpg

Upgraded from the stock 78mm throttle body to a 92mm
https://i.imgur.com/zLHrmO8.jpg

My previous Suspension Techniques sway bar was actually rubbing on my GTO oil pan ever so slightly, so i ordered a GK Tech sway bar for almost 3" of more clearance
https://i.imgur.com/HyJC0GT.jpg

after much thought, i decided to swap out my MasterPower T76 turbo for an On3 Perforance Billet 7675. Better flowing than the MP76, very comparable to the Precision 7675 at half the price, and the LS and Mustang guys have been giving props
https://i.imgur.com/LkiCCtw.jpg
https://i.imgur.com/0aUDLeM.jpg
https://i.imgur.com/8xlxmmR.jpg

I bumped up from my 80lb injectors to a set of 95lb/1000cc injectors. I'm planning to convert to E85/Flex Fuel later in the year and took the plunge now:
https://i.imgur.com/77yukrp.jpg

Now for things that needed to be done.....
1. redoing the turbo setup for the new hood
2. cooling issues....this thing still gets hotter than i am comfortable with

Ended up cutting the new hood for Aerocatch latches :( Sad day getting it towed from the old house to the apartment
https://i.imgur.com/PqtzCEu.jpg

New hotside ended up being modified LS truck manifolds due to timing, i just wanted to get it running while i continued to work on my tubular manifolds. Welded some stainless tubing and vbands to the cast iron manifolds. Had them coated and wrapped the stainless portion
https://i.imgur.com/WZo72cr.jpg

2.5" 304SS crossover with flex section and used a exhaust cutout as the 2>1 merge
https://i.imgur.com/eLFT4SJ.jpg
https://i.imgur.com/wK4pgdo.jpg

Used a Turboflanges.com 2.5" round to T4 304SS flange
https://i.imgur.com/vTSzrFX.jpg

Added a VS Racing 44mm wastegate and dump tube
https://i.imgur.com/ghldehI.jpg
https://i.imgur.com/AiHcMui.jpg

Made a 3.5" downpipe that transitioned to 3.5" oval for ground clearance. It's only complete to the transmission for now. Plans will be to copy my Greddy DD layout and go from 3.5" > dual 3" > 3.5" tips (Greddy DD was 3" > dual 2.5" > 3.5" tips)
https://i.imgur.com/uAQOqOu.jpg
https://i.imgur.com/WBEzM76.jpg
https://i.imgur.com/BJezZw6.jpg?5

Shitty cell phone vid at idle
sL0f_e9YixA

Next i went on to fluid cooling, in addition to the oil cooler i added earlier

Derale 4 row powersteering cooler mounted to upper radiator support
https://i.imgur.com/6f5yBnJ.jpg

And finally on to radiator/cooling which is still in the works
for now the same Griffin 24x16x3 (19x15.5x2.5 core) radiator but with a 16" Spal Extreme fan (2500cfm)
https://i.imgur.com/iv58uns.jpg

Converted an Ebay aluminum overflow tank to a custom surge tank. Actually modifying this for more capacity and to be self bleeding.
https://i.imgur.com/S1s9ufO.jpg

Made a couple of block off plates to fill the gaps around the radiator and lower core support
https://i.imgur.com/WCQnoKv.jpg
https://i.imgur.com/I0NYCKP.jpg
https://i.imgur.com/W0T4IDA.jpg?3

I also have a LRB undertray to help with airflow while driving
https://i.imgur.com/A5vc3eb.jpg
http://lrbspeed.com/product/s13-undertray/

Cooling at idle is still an issue, so i'm making a fiberglass shroud for the Spal fan as a last ditch effor before i splurge for a slightly bigger radiator.
made a form based on the dimensions of the core and the fan
https://i.imgur.com/ahK7b0o.jpg

wrapped in a $5 Wal Mart polyester blanket
https://i.imgur.com/5pQrpdT.jpg

then a couple layers of fiberglass fabric and resin
https://i.imgur.com/j3XZwt9.jpg

Need to trim, prep, and paint after it's fully cured to see how it really works.

Cooling has been the thorn in my side for the last 2+ years. I have a pair of N1 style ducts that i have available but i want to keep that as a last resort. I'm seriously considering an Origin Stream or VS racing front bumper so i'd like to have cooling down before having to modify the new bumper.

Hopefully i have more promising updates soon!

[91 240]

So yet again another long gap between updates. This is going to have a few changes over the past 2 years.

I ditched my entire cooling setup and started over, however looking back i might have actually ended up being a dead Optima battery. It would hold a charge but as it heated up it would slowing start dropping. Oh well, new battery and these changes have been good so far.

Ended up with a slightly large Griffin Dual Pass radiator with Derale dual fans. I had to notch about 1/2" out of one of the end tanks to get it to fit within the frame rails.

https://i.imgur.com/59lstyN.jpg
https://i.imgur.com/wdnFEbE.jpg
https://i.imgur.com/eZhSUq1.jpg

I had to push the radiator as far forward as i could, which meant relocating the headlight motors using the Auto-Collect Storm brackets

https://i.imgur.com/Hqt0z4Q.jpg?1

With the larger radiator/fan combo, i had to redo my turbo setup. I had to pull it in about 2" closer to the motor to clear the fan shroud. Stuck with the same 2.5" stainless

https://i.imgur.com/Mh0kEMA.jpg?1
https://i.imgur.com/B9c9hQB.jpg?1
https://i.imgur.com/9dvl8Ey.jpg?1

Ditched my old ebay FMIC for a Treadstone TR1245 31x12.5x4.5

https://i.imgur.com/sxNECfP.jpg?1

Then made some new IC piping. Got some good practice on my aluminum welding.

https://i.imgur.com/V2ZyDJ8.jpg?1
https://i.imgur.com/pFvi6hg.jpg?1
https://i.imgur.com/rj1eDH4.jpg?1
https://i.imgur.com/vbWdl0r.jpg?2
https://i.imgur.com/xEW3qDq.jpg?2
https://i.imgur.com/Md8EOvN.jpg?1
https://i.imgur.com/GznL1GO.jpg?2
https://i.imgur.com/Y1q4U3G.jpg?2

From there I wanted to finish my exhaust. I used my Trust DD and made a jig to step up the piping size.

Trust DD is 3" > two 2.5" > two 3.5" tips.
My exhaust is 3.5" > two 3" > two 3.5 > tips using a Vibrant Race Muffler

https://i.imgur.com/VFDpjp0.jpg?1
https://i.imgur.com/gFoKMjZ.jpg
https://i.imgur.com/JPXtk05.jpg?1
https://i.imgur.com/109sjMk.jpg?3

Little idle clip
https://youtu.be/lyLGZJe_ceA

I did a little suspension work. Finally added the SPL mono bearings i've had sitting for a while. Z32 uprights, lower shock bearings as well as all 3 rear arm bearings.

Little cleaning, before and after
https://i.imgur.com/P7WLT1t.jpg?1
https://i.imgur.com/hsteRy2.jpg?1

Got some new rear wheels and tires, same style just went 17x10.5 +27 with 275/40's to 18x10 +40 with 285/35's. The 17's were too wide and didn't want to try pulling the fenders that much. With the 18's I ended up only having to do a mild roll/pull...maybe 1/2". Gained almost 1.5" of suspension travel

Before
https://i.imgur.com/pxU6BJt.jpg?1

During
https://i.imgur.com/HHfupzv.jpg?1

After
https://i.imgur.com/OiVA4J6.jpg?1

I just finished up my turbo intake piping. Needed to get creative with some pie cuts to get it where i needed it. This took about 6 hours of welding

https://i.imgur.com/dB5dafc.jpg?1
https://i.imgur.com/QZudSfR.jpg?1
https://i.imgur.com/jyJlPeX.jpg?1

I should be finishing up my front suspension this weekend. Koni yellows to replace the KYB AGX's i had with the Ground Control coilovers. Adding T3 camber plates and their upper spring hats

https://i.imgur.com/ydf0pwp.jpg?1
https://i.imgur.com/TGapl6O.jpg?1

Got a new bumper that's going to need some work to fit. VIS Racing knock off of the Version Select V4

https://i.imgur.com/KgR78AJ.jpg

Pretty much how it sits right now.

https://i.imgur.com/sQmtvvN.jpg?1

I have a few more little things to wrap up before i'm ready to have it tuned again. Hopefully something in the next couple of months.