Grapplers build thread (fire rebuild)
 

So for those of you that didn't know I had a small PD related fire and decided to go turbo. This is just a couple of pictures during the process.

Here is what the car looked like after the fire doesn't look too bad.

http://i194.photobucket.com/albums/z...d/DSCN0027.jpg

Here is where I am as of yesterday, Hopefully today I can get the rest of the rats nest off and the stupid rusted bolts on the battery tray out and remove the fan shroud.

http://i194.photobucket.com/albums/z...d/DSCN0035.jpg

Quick picture of the nastiness the fire left for me Don't worry I have rags in the intakes I just took them out for a quick second for a quick photo.

http://i194.photobucket.com/albums/z...d/DSCN0029.jpg

Cause was found stupid Pulsation dampner...

http://i194.photobucket.com/albums/z...d/DSCN0032.jpg

Here is whats left of the OMP spider

http://i194.photobucket.com/albums/z...d/DSCN0034.jpg

Few parts going in...

http://i194.photobucket.com/albums/z...d/DSCN0026.jpg

http://i194.photobucket.com/albums/z...d/DSCN0025.jpg

http://i194.photobucket.com/albums/z...d/DSCN0022.jpg

Aeromotive FPR its the one with -6an
SS fuel lines
Fuel Pressure gauge
550cc injectors
S5 Turbo / Mani (Turbo in the picture is s4 I know)
HKS filter
TII UIM LIM TB etc.
Greddy Compression Tube
Walbro 255lph Fuel Pump
Greddy EGT and Wideband
Autometer Boost/Vacuum Gauge
Racing Beat Resonator
Turbo Downpipe Coated
Rtek 2.1
FD alternator and Dual pulley
Air to water intercooler Kit
Block off Emissions and OMP

:icon_tup: Nice.... we MN FC guys need to get together and meet this summer when we have our cars running again :lol: Looking forward to seeing updates!

Sucks about the fire, I almost suffered the wrath of the leaky PD before, but I got lucky. Nice collection of parts though, looks like you're on the right track :icon_tup:. So you're going 6-port turbo? Keep us posted.

I remember reading your fire thread...

Nice build. Any plans for a bigger turbo down the line?

MN FTW.... NOT... winter sucks...

It would be great to have a meet!

Good luck with the build... I'm close to you if you ever need a hand to wrench with.

air to water...

this should be fun

You need to put some BBQ sauce on that harness :D At least you have time to make a few upgrades. You've probably seen this but in case you haven't : http://fc3spro.com/TECH/FAQ/pd.html

Definitely sounds good to me. and updates are otw.

Yeah I should have paid more attention to the Gas smell... but too late now.

Yep I am going the 6 port turbo route.

Eventually I will problably go with one of the BNR hybrids but for now I am just wanting to get the car running. Tired of running around in my gf VW Beetle (I hate slushboxes)

Yeah winter is cold and long and boring. I will say I would rather have a MN winter over a ND winter any day though the roads here actually get cleaned and I can see the ground.

:nod:

Tried some sweet baby rays on it still tastes like oily charcoal. I did actually look at that link right after I had my little fire. thanks for posting it though.

Small Update

Got some Gaskets in from Atkins Rotary and Pineapple racing as well as some block off plates and such.

http://i194.photobucket.com/albums/z...d/DSCN0038.jpg

Removed the Rats Nest of nasty emissions pulled the Airpump out, Got the LIM off and removed the 6 port sleeves. Managed to get the Exhaust Manifold off after I sheared half the bolts off on the heat shield. Tomorrow I am going to pick up some PB Blaster for the stubborn nuts and bolts on my Pre cats and Main cat.

http://i194.photobucket.com/albums/z...d/DSCN0039.jpg

Ordered some more parts today.
Nordskog IAT gauge
Silicone Adapters and Piping
Rotary Performance Midpipe ( goes between DP and Main Cat)
Taurus 2 speed Efan
AFM adapter
AN Fittings for Turbo Drain
Fan Relay
AN Fittings for A2W Kit

So if you're pulling the emissions crap, why order emissions crap gaskets...?

for the block off plates?

I guess...but by the time you buy one gasket you could have 2 tubes of RTV...

What is the purpose of the orange tube sleeve in the picture? I think it says "Dixon Valve".

http://i194.photobucket.com/albums/z...rosleeve1a.jpg

Its a piece of heat shield tubing for gauges and such.

I meant where are you going to use it?

I plan on using most of it to cover silicone line from the rear housing coolant nipple and modifying the stock line to accept a barbed fitting.

Whats left will be used on my wide band gauge sensor.

So will you get a new PD or use a banjo bolt? ;)

Nope going full braided ss line and a aeromotive FPR :egrin: using Metric to AN adapters on the fuel lines and going ss all the way back to the hard-lines.

Well got some more work done got the entire exhaust system out Cat forward. This took most of the day (no joke)
I soaked all the nuts and bolts in PB blaster and cranked on it with a wrench till it came off (no power tools for me :( )
http://i194.photobucket.com/albums/z...d/DSCN0041.jpg

This is what is going in to replace it Ceramic coated DP Rotary performance Precat replacement Pipe and a Racing Beat resonator (not shown in pic)

http://i194.photobucket.com/albums/z...d/DSCN0048.jpg

Gauge holder came in I wish I could have gotten it in just plain black plastic but I guess its CF better then nothing :lol:
I will be putting my Wideband EGT and Boost gauge in this I will be using a Dremel to make the wideband fit as it is a 60mm gauge.

http://i194.photobucket.com/albums/z...d/DSCN0047.jpg

Got some more SS line in -10an for my A2w setup and my turbo drain fittings :D Also fan relays for the Efan I will be getting in tommorow and for the fan on the A2W radiator.

http://i194.photobucket.com/albums/z...d/DSCN0045.jpg

So yeah waiting for more parts to come in... day in day out

Wow just realized its been a while since I have given an update.
Haven't had much time of late to go work on my car with Work/School

However I finally got a chance to go out and work on my car again.
If only for a little while I managed to get some stuff done.

Today:

Removed Fuel Pump assembly I will be replacing the Pump with a Walbro 255lph setup :D
http://i194.photobucket.com/albums/z...d/fuelpump.jpg

Finally got the last bolt out of the Battery tray (thank you home depot for the screw extractor)
Removed the Fan shroud from the Radiator
Sorry for the stretched images my lovely assistant was in class (with the good camera :'(
http://i194.photobucket.com/albums/z...d/radiator.jpg

Removed The rest of Cold start assist Assembly (Resevoir and tubing)
Temporarily took out the Cruise control in order to get to the resevoir and remove the wiring harness.

Plan for tommorow is get the clutch fan off ditch the OMP finish up the Fuel pump assembly get the turbo LIM on and start running the SS fuel lines (crosses fingers)

looks like you're doin all that work in a cramped storage unit. that's gotta suck. I had a PD fire about a year ago. I had a full garage, but it was unheated and below zero during most of my repair work. Salamander heater made it bearable. Kept the NA, so my repairs were limited to the usual suspects. my vaccum spider literally disappeared. I think I finally found it on top of the housings. it ended up looking like a small charcoal brick.

Yeah mine looked about the same its just a nice little piece of burned plastic/rubber. I don't really mine the storage unit though the people that own it are really cool about me working on my car there. Its not heated but I think the coldest its ever gotten couldn't be less than 55 degrees.

Time for an update woo hoo!

Ok so been getting stuff done here and there It seems like not much but its getting there...

Fitted the gauge pod in its gonna overlap a little bit on the Warning lights but I don't mind at this point.
http://i194.photobucket.com/albums/z...ild/Gauges.jpg

Ordered the right fittings for my fuel rails.... one is 12mm x 1.5 the other side is 14mm x 1.5.... :banghead:

http://i194.photobucket.com/albums/z...ANFittings.jpg

Got my Turbo Drain Fittings from ATP :D

http://i194.photobucket.com/albums/z...bofittings.jpg

Taurus Efan hurah for less engine bay clutter.

http://i194.photobucket.com/albums/z...build/EFan.jpg

My new Emissions harness that is in great shape :happydance:

http://i194.photobucket.com/albums/z...NewHarness.jpg

Silicone Vacuum lines got here too

http://i194.photobucket.com/albums/z...conetubing.jpg

I also got some AN wrenches in (adonized aluminum) so I won't scratch/destroy my fittings. However UPS is closed on Saturdays/Sunday So I won't get to work on the Fuel system till then.

Got the RTek installed today well sort of installed I still Need to pull the old harness and get the new one put in. I can pick up my -AN wrenches tomorrow :D

I am hoping to finish up by the end of the week if all goes as planned (crosses fingers)

Mocked up the Taurus E-fan with some crappy zip ties I will put some better ones in and make it fit nicely later when I have everything where I want it.
I also mocked up the turbo and everything looks good on that end hopefully get the turbo, EGT and Exhaust installed tomorrow maybe even start on the fuel system
Kick plate
http://i194.photobucket.com/albums/z.../KickPlate.jpg

Old ECU
http://i194.photobucket.com/albums/z...ild/Oldecu.jpg

New Rtek ECU !!!!!
http://i194.photobucket.com/albums/z...ld/Rtekecu.jpg

Getting closer to being done still a ways out but I can't wait to be done and get the car running.

btw... it is really freaking cramped trying to install/takeout that ecu. I am 5'10" and about 150lbs and I had a hard time getting in there.