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.

Update time again...

Well lets see I have gotten a bit more done since the last time I posted here.

Tapped and Threaded EGT Fitting
http://i194.photobucket.com/albums/z...00221-1346.jpg
http://i194.photobucket.com/albums/z...00221-1346.jpg


I started porting out the LIM after destroying several High speed cutoff discs hewing a rough shape out my dremel died...
So I took it to FNR and they are going to finish for me (thanks guys)

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

I Modified my S4 waste gate to fit the S5 turbo and it works !!!! this made me very happy a little snug but the actuator works fine and the movement of the flapper is not impeded that I can tell.

(I had a cold so don't laugh)

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I also before my dremel died cut up the CF Gauge holder I got from summit and made it so I could fit a 60mm gauge :D
I think I might place the gauge in the glove-box and open it when I need to tune since I am slightly leaning towards a sleeper look

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

Got my HKS Filter all mocked up onto the AFM and I do have a replacement element on the way its just taking forever to get here... good thing I bought 2

http://i194.photobucket.com/albums/z...00223-1614.jpg

Turbo and Manifold all bolted up and looking amazing in the engine bay :D I still have to install all of the lines like oil and coolant feed and drain but its on the list of things to do still.

http://i194.photobucket.com/albums/z...00223-1614.jpg

I also managed to find a rubber coupler to install a make shift TID 3" to 2" will work for now till I get something proper put in.

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

few other things as well I can't remember off hand or don't have pictures of but keep looking for updates.

Cool. Your making progress. You should ditch that HKS filter though. When they break down you end up sucking little pieces of that foam into your engine.

that sucks.... what would u recommend? an apexi power intake?

Yea its one of the best, that's what I run, they come with a really good mounting bracket to hold it all in place too. I will look for a comparison chart of air filters for you.

here ya go http://www.mkiv.com/techarticles/filters_test/2/

I would recommend K&N. There is another good comparison that was in a thread recently around here somewhere too.

for the oil drain you could have used the stock s4 oil drain


for the oil feed make sure you make it from hardline im assuming you are taking it from the oil pressure sensor (it'll be cheaper and look better)

If you go to home depot they have sanding drums that attach to a drill and one of them is the perfect size for the porting job and it literally takes 30 mins to finish the job... i used a small drill bit and used that to get the size and rough in for it and the drum smoothed it out

You are using an S4 lim? i hope its, alittle bit different than the S5 Oh wait nevermind s5 can go on to s4 easier i was thinking vice versa

what are you using for engine management?

Oh and make sure you use t2 upper and lower fuel rails they dont mix with the n/a ones unless you cross the fuel lines

Is this a N/A to turbo build? Its very interesting...

I have put 6,000 miles on my hks filter foam and have had no issues with it breaking down.

A buddy's s13 has had it much longer with absolutely no problems.

I don't think a quality company like HKS would continuously sell a bullshit product.

Do what you want though, it is your filter........and i HAVE heard of this complaint via the internet (just never seen or heard it in person).

john ny

Thanks its good to get some feed back.
I have heard about people having issues with the filters most of them are cheapskates who don't want to spend $25 on a filter element they wash them and wonder why it disintegrates.

I could do that I haven't set up the drain yet I am debating between tapping the front housing or the oil pan I have AN fittings for both though we shall see.

I am using an oil filter pedstal and using a modified hardline that came with the pedastal when I bought it.

I killed my dremel :(

It lines up very nicely I just need to finish getting it ported

Rtek 2.1

Primary fuel rails are the same
Secondaries won't line up so I used a turbo secondary fuel rail


Yes its an N/a turbo build

I am getting 2 new elements in the mail so I should be good to go :D

I totally agree with you though it shouldn't cause any problems.

Nooo primaries are not the same i made the same mistake on my car i had fuel starvation about 5k because the FPR was on the wrong way

then again i tryed it with a s5 n/a primary and s4 secondary :/ looked the same at the time lmao

Nice rtek will run it mint I'm using an emanage i prefer tuning via a laptop than a pda i'm still using the n/a primary injectors and t2 secondary result is it drives exactly like a stock n/a when out of boost and below 4000 rpm

Good luck with the build dude you're going to love slapping t2's around lol

just make sure you get a wideband and keep an eye on knock

seriously dont tap the oil pan the front cover already is already setup for the oil drain the bolt holes are already tapped all you have to do is drill the hole for the oil to go through, just pack the drill bit with grease so it catches some of the shavings and change the oil after or flush some oil through that hole to get the shavings.

thats what i did on my S5

Allright so its that lovely update time again

First thing I found out is Racing Beat resonator is not a direct Main cat replacement its about 3 inches too long for it which made a few headaches...
so the main cat is back on all the horsepower robbing goodness of it.
Second Thing is I found out how much of a pain it is going to be to drop the oil pan which is the main reason I didn't get to go to the auto x class this weekend :(
Third I found out the efan I had is bad so... either its back to the good old clutch fan or I find a new efan... which isn't a bad thing just means I have to more conservative with my IC piping.
Fourth thing SS line hurts the fingers a plenty wear gloves

Anyways on to the pics :D

Here is the Modified LIM I made took forever with a dremel.
I also put up a couple close ups of the port work.
http://i194.photobucket.com/albums/z...ild/LIMBig.jpg
http://i194.photobucket.com/albums/z...ld/LIMLeft.jpg
http://i194.photobucket.com/albums/z...d/LIMRight.jpg

Here is the SS parallel fuel system I have setup before its installed its -6an line running to the hard-lines
That red tube thing is a 40 micron fuel filter Surprisingly I only used about 10feet of SS line to make the fuel system.
http://i194.photobucket.com/albums/z...00421-0014.jpg

And here we have it installed in the car that's an Aeromotive FPR mounted to the firewall and that blue vacuum line will be hooked up to the LIM Soon
http://i194.photobucket.com/albums/z...00421-2000.jpg

Here we have the turbo mounted up properly with the main cat installed not the resonator...
I ended up blocking off the water cooling lines all it does it help cool down the turbo. So as long as I let it cool down properly i.e. let it sit for a few min at idle I should be good to go.

http://i194.photobucket.com/albums/z...00421-2148.jpg

I finally have most of the wiring done in the engine bay I have rewired the FD alternator
to work in my FC and it may look shoddy but its hard to hook up 4 wires of totally different gauges together.
All that's left to to as far is wiring is concerned is hookup the A2w pump and fan to the electrical relay and from the relay the harness.
I need to mount the reservoir and pump first though :(
Now I have the UIM manifold and TB installed here I have hooked up a brand spanking new TPS (most expensive part of the car I swear)
I also hooked up the IAT sensor everything lines up with the fuel system so thats all good.

http://i194.photobucket.com/albums/z...00422-1942.jpg

I started to run the IC piping and heres a nice picture of how the DSM bov is going to sit in the car.
Since I might have to reinstall the clutch fan I have figured out a strange way to route the IC piping if it works.

http://i194.photobucket.com/albums/z...00422-2125.jpg

Part 2


Last picture I promise for today Heres how the engine bay is sitting as of yesterday it looks good and I am happy I am getting so close to being done.
Its been hard to keep motivated to finish but my lovely assistant helps keep me going.

http://i194.photobucket.com/albums/z...00422-2125.jpg

Ok I lied one more picture this one is of my lovely assistant helping me install a new filter element on my HKS filter :D

http://i194.photobucket.com/albums/z...00411-1530.jpg

Things to do before its finished:
Tighten Downpipe nuts
Attach Oil feed line to the turbo
Tap Pan and attach oil drain.
Attach Fuel Feed line to the hardline
Remove old Fuel Filter
Mount A2w Resevoir
Mount and wire A2w Pump
Finish IC and IC pipe running
Run Vac line for boost sensor
Wire in Gauges

Start car

Yeah... so more pictures

Current Photos before I left yesterday night.

http://i194.photobucket.com/albums/z...00522-1738.jpg

Sorry for the crappy quality
IC piping as it sits right now I wish I had that efan working but $$$ is getting a little tight so this will have to do for now. Its not the best routing but it works still is a lot of bends though. I eventually will get an Efan again and re route the piping for better flow.


http://i194.photobucket.com/albums/z...00522-1757.jpg

Mounted the resevoir finally :happydance: its going to sit like a modified Vmount setup I have seen a few people do this on rx7club forums they say it works great for them so who am I to argue. I am also going to mount a 7 inch fan to this thing to pull air from under the car. Maybe even rig up a scoop or something just ideas floating around for now though.

http://i194.photobucket.com/albums/z...00522-1757.jpg

The Resevoir sits really well I had to bend a couple of the A/C hardlines a bit but its never really worked anyways so I am not too worried about it I need to grab another couple of things to totally secure it but for now its a good test fit.




Things Left to do

Mount and wire A2w Pump
Finish IC and IC pipe running
Wire In Gauges

Start Car

Great progress, that piping though.... :/

well I couldn't help it but I redid the inter-cooler piping and found my leaky o ring that was making gas puddle under the car.

Much nicer now :D
http://i194.photobucket.com/albums/z...d/ICpiping.jpg

This little bugger caused me all sorts of problems.

http://i194.photobucket.com/albums/z...uild/Oring.jpg

I would really consider running the coolant to the turbo ..... the turbo's are inefficient as it is and the hotter it gets the worse it will be, and you dont want your turbo over heating and blowing

+1 ... especially since its not like you have a good reason not to, it looks like all the lines are there, all you need is a gasket or 2.

Looks like you prolly could've done it w/ 8ft ;)
Have you pressure tested those lines yet? I did that exact setup on a previous TII, SS lines were a pain in the ass (well...in the fingers to be accurate) and it took a few adjustments to fix all the little leaks. I'm gonna re-vamp my current fuel system, but I'm either going w/ nylon or a push-lok type hose this time around.

Also, this coupler WILL melt. It's fine to get it running and sort out preliminary issues but it is far from a long term solution .
http://i194.photobucket.com/albums/z...Matachment.jpg

I am picking up some hoses and I will run a line to the nipple on the rear housing and one to the water pump housing.

Haha yeah I have a little extra.

I made one line and then I bought something called a Koul tool best money I ever spent.

I did pressure test the lines I needed to tighten a couple of fittings but its all good now.


Thats been switched out for a proper TID ;)

Wow... its been 5 months since I posted anything...

Well... Its started but wouldn't hold an idle for a while so I brought it to MAP or Modern Automotive Performance they did some awesome work on my car and found about a million and a half boost leaks that they fixed so it holds a proper idle. They also found a few things that I need to fix like a motor mount that this whole time had been held on by a standard nut instead of metric so it was stripped out, and they fixed my oil drain so oil wasn't running out of my down pipe basically all the things i did wrong they fixed and they were awesome to deal with so huge shout out to them.

Downside is things are back on my to do list... again

:things to do:
Replace motormount
Replace leaky BOV/recirculate
Get Efan and optimise I/C piping.

Parts sitting in my room right now...
http://i194.photobucket.com/albums/z...d/DSCN0386.jpg
Huge Efan
Himni Racing Motor mounts slightly stiffer than stock but should be ok for DD
Greddy RS with Recirc supplies and flange
Greddy turbo timer
3" 90 degree coupler
-10 90 degree fitting for drain
Still not done ordering stuff :(

I also recently realized why I hate buying things from ebay...
http://i194.photobucket.com/albums/z...d/DSCN0384.jpg
http://i194.photobucket.com/albums/z...d/DSCN0385.jpg

One on the left is the one I ordered one on the right I got for free from the guy that sold me the Greddy RS
Per the Ebay ad the one on the left is supposed to have the flange mounted parallel to the pipe...
The piping is meh at best its rolled, it has a seam line that runs down the bottom of the pipe
Whoever welded this did a terrible job its not flush what so ever with the piping and the flange is warped

serves me right for trying to save a couple bucks by ordering a pipe + flange instead of 2 couplings and t clamps... grrrr

PROGRESS!!!!!

Turbo drain 2.0
http://i194.photobucket.com/albums/z...d/DSCN0388.jpg

Turbo inlet duct 2.0 (now with recirculation fitting)
http://i194.photobucket.com/albums/z...d/DSCN0387.jpg

New I/c piping arrangement :D
http://i194.photobucket.com/albums/z...01116-1932.jpg

Efan in place :D :D :D (ignore the untrimmed zipties)
http://i194.photobucket.com/albums/z...01116-1946.jpg

Whats left
Wire Efan
Install Motor Mounts
Reinstall TID and recirculate

THEN ITS DONE!!!!

oh god.

Dude where in MN your from,I did not know there were any more people drivein fc's in MN

looks like a botch job, sorry :[

you really should install the manifold and turbo heat shields, those paper exhaust gaskets won't last long, you really need coolant for the turbo to prolong its life, that TID..., they make fasteners specifically for attaching a fan to a radiator that are cheap and available at parts stores, though that fan may not move enough air anyway, why are you using an A2W setup?