Josh's New Build Thread
 

I've been looking around the FD section for a little while, but have been around in the FC community for quite some time. The link to my old FC build is in my signature.

So the story for the new build begins like this: My FC is euro spec and is just shy of the 25 year requirement for bringing it back stateside. So rather than hassle with storing it until shipment or doing any one of a million other options, I decided to make a move. A buddy from the local car scene had wrecked his LS3 swapped FD at the track and decided he didn't want to work with the platform anymore (he's putting the motor in a 350Z). So he offered it up for $1000 as a non-roller, or $1500 as a roller.

Needless to say, I jumped on it. I managed to sell the suspension, wheels and exhaust from the FC for enough to cover the cost of the roller and the FD specific parts I would need (trans, PPF, catback, etc). I also acquired the fenders I needed. I'll be swapping my S4 motor into the FD, for now. I'm also going to reconfigure my custom v-mount to install it in the FD. I'll put my RX8 bell housing on the FD trans so I can retain my OS Giken twinplate and not have to use a movement alteration kit. Finally, I'll be transferring most of my custom AN fuel system over to the FD.

Of course I'm planning to do some chassis stitch welding and paint as I go along, since I have to do body work anyway. Stay tuned here for the resurrection of this poor soul.

Here's a couple pics from when we picked it up:

http://i235.photobucket.com/albums/e...psiusfit5n.jpg
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BRING. HER. BACK. I'll be watching! Good luck with your build mine's white too! :)

Some bonus parts were included, that I hadn't counted on, when I picked her up. The car used to have a authentic Burnout kit on it, but it was thrashed in the wreck. Luckily he had the factory front bumper to give me. Also, it came with an extra hatch, that I will probably use for mounting a wing for track use.

Please don't put your S4 motor in that. You may think you are saving money, but if you sell you're S4 motor and save up for a couple of months and just buy an REW you will save yourself so much work and have a much better power plant.

I don't have a few months to spare. I have to get the car ready to go on a boat back to the states ASAP. I have all the major parts for my REW motor (housings, irons, rotors, e-shaft, manifolds, etc), but not the seals and gaskets. And I don't want to half-ass the motor internals. Not to mention, the European rotary market is very small and much higher priced than the U.S., so selling the S4 motor in a timely manner would be a fairly difficult task.

I have plate steel and a good welder (and lots of experience). Also, the S4 motor already runs on a Haltech, so I basically just transfer over the harness and weld up some motor mount brackets (or use mild steel and modify the subframe) and she's good to go. The S4 motor has a hybrid turbo and is pushing about 400hp, so it's no slouch.

I understand that, for most people, it would be a waste of money because they're paying for labor and parts/materials, but in my case, since I have everything on hand, I am definitely saving money. Like I said, getting the car self-powered and shippable is the main priority.

Once I get stateside the car will get stripped back down, put on the rotisserie and stitch welded, and it'll get the fresh motor...along with all the other goodies I have in store for it.

Good luck wit your build....hope it all works out.

I have some goodies on the way. I ordered some lower control arm bolts, headlight covers, and a driveshaft. I also got a good deal on a Banzai oil pan brace and JDM motor mounts for my S6 motor. I sold one of my cars earlier than I had planned, so I might be able to get the rebuild kit for my FD motor. It'd be nice to only have to install the motor once, but we'll see how it all shakes out.

Best of luck! Hopefully you can bring it back from the dead :)

I managed to scrape together the cash to get the Atkins master rebuild kit (needed a new chain and such for my oil pump), with cryo treated side, corner, and apex seals. So, I'll get the motor put together and dropped in. Before that happens though, I'll need to clean, prep, and paint the engine bay. I've also gathered some more parts.

One hurdle that was keeping me from starting to work on her was needing to get my daily on the road. Well that's done now, so hopefully I'll be posting more progress soon.

Here's a pic of how she sits right now:

http://i235.photobucket.com/albums/e...ps386d9536.jpg

Can't wait to see how the FD comes along Josh! Good pickup

Got a whole slew of parts ordered today.

From Pineapple Racing: BT idler pulley kit
From Banzai Racing: fuel rails, 725cc and 1000cc ID injectors, and block off plates.
From Full Function Engineering: Hall Effect trigger kit

That should be everything I need to get the FD in good running order. I also finished deconstructing the FC today. I'm looking forward to finally putting a wrench to the FD.

A $1000 bucks.....sounds like a freak'n score! I'll be watching!!!

nice I`m glad to see FD rebuils in europe =]

Finally an update. Today I received my FFE trigger kit and my Pineapple Racing idler pulley kit. Big props to both companies! FFE actually contacted me when they got my order, and asked if I was military, because of the APO address, and hooked me up with a discount. Pineapple threw in a second belt, of a different length, at no charge...just in case my guess at the necessary length was wrong. If you haven't already, you should check out both companies.

I got the garage cleaned up a little over the weekend and got my work bench cleared. So tonight I started cleaning rotors and getting ready to clearance the side seals. Higgi will be making the trip from the Czech Republic this weekend and will be helping me put the motor together.

Here's some pics:
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Yesterday I finished cleaning up the rotors yesterday and cleared my first seal. Tonight I finished the first rotor. Side seal clearancing is rotary hazing, LOL. I'll be glad to be done with this part, tomorrow night.

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Finished clearing my side seals. Now I just need to get the housings painted tomorrow and I'll be ready to assemble on Saturday.

That's one small step for me, one giant leap for my FD.

The motor is all put together. Higgi helped me make sure I didn't destroy anything or lose anything, or other wise screw anything up. I plan to paint the housings with the motor together. I decided to keep the black paint on the irons and do white for the housings. So I'll knock that out this week and get the oil pan brace and oil pan installed. Then I can get the transmission mounted.

The weather is quickly improving here, so it's entirely possible I may be able to paint the engine bay before putting the motor in. Also on the docket is getting the diff swapped out and the bearings replaced. Lots to do.

Here's some pics:
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More pics:

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With the motor all together, it's time to start working on the chassis.

Got my SuperPro bushing kit from AutoRnD today.

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Gotta get the motor painted tomorrow.

Got some motor paint done. Gotta clean up some of the edges with some black high temp, and this is only the end of stage 1. I finally received my order from Banzai (stupid postal system) and mocked up the new fuel system. Going to get a couple fittings on order from ANplumbing.com and I'll get good to go.

Here's some pics:
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Snagged some goodies for the car today. Picked up a R1 dual oil cooler setup (with mounting brackets and hoses) for cheap, new front fender well liners, and a Pettit AST.

Its coming along nicely. Motor work is looking good.

Little update:

I managed to sell my old S4 motor and got some more parts on order. Since my separation from the AF has been approved, I am now under the gun to get the car running, so that I can ship it.

I have a set of Stance coilovers on the way, from coilover-store.com. They cut me an awesome deal and threw in free priority shipping, which is a big deal for those of us stationed overseas.

I also have a set of factory twins on the way. I had initially planned to run my hybrid S4 turbo, but it was going to be a half step anyway. This way I can put the factory twins on (non-sequential) and run an off-the-shelf downpipe, to get the car going sooner. Later this year I'll put in a BW 7670 1.05AR.

In addition to the coilovers, I have mazdatrix competition sway bar brackets, ST sway bars, and adjustable end links on the way. Combined with the R1 strut tower bar and the strut tower bar in the rear for the seats, and the SuperPro bushings, I should be all set in the suspension department.

I'm hoping to get the engine bay paint done this week, so the motor can go in and I can get the v-mount welded up. Lots to do.

Got the paint finished on the motor. I have some more ideas to fancy it up, but it'll have to wait.

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Today I got the oil pan cleaned up a the studs for the Banzai pan brace installed. And then proceeded to drop a nut down the drain passage that's on the rear iron. It's not coming back out of there, so hopefully it won't cause any issues. Hoping to knock out the fiberglass hood tomorrow.

I managed to get the errant nut out of the rear iron...glad I went after it, as it was chillin' right be the stat gear. Oil pan is on, with the brace. Just need to do the gasket matching on the intake manifold and all I'll be waiting on is my turbos to arrive.

My coilovers arrived from coilover-store.com in record time, and with a free Stance t-shirt. Yesterday, I got the front suspension swapped out and got my SuperPro bushings done at the same time. Today I tore apart the rear suspension and got all the bushings swapped out. I'll put it all back together tomorrow. I'm also going to drop off my differential to get it swapped out and get all the bearings and seals replaced.

I have secured all the parts I need, except for a midpipe, to fire the motor once I get it in.

So close.