The FC build challenge
01-13-13, 12:41 AM
#51
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today i built a turbo from pieces, i've never built a turbo! and it shows, its not as "spinny" as i'd like, it'll need to come apart again... its just stock.
then of course we really get to see why i don't like turbo cars, all those pipes!
then of course we really get to see why i don't like turbo cars, all those pipes!
01-15-13, 06:13 PM
#52
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ok here are the turbo build pics. i started with random junk lying around. i don't need it to run very long, as its going to get a hybrid pretty quick. this was saturday
01-15-13, 06:17 PM
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i started with the easy stuff, i lapped the backplate, and radiused the edge a little.
then i radiused the inlet to the turbine, and you can really see how bad it is!
then i ported the WG a little. i'm not really trying to keep boost to "stock" levels, so i didn't go nuts, but it would be nice if it didn't spike too hard.
then i radiused the inlet to the turbine, and you can really see how bad it is!
then i ported the WG a little. i'm not really trying to keep boost to "stock" levels, so i didn't go nuts, but it would be nice if it didn't spike too hard.
01-15-13, 06:19 PM
#54
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turbo assembled! i screwed something up and had to do it again so i did, turns out the thrust thingee was backwards.
01-15-13, 06:23 PM
#55
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then i used Mr Ko's thermostat cover, and was able to trim the stock hose to fit! you can also see the trick K2rd pulley it grew on the crank.
so at some point i mentioned the mystery wires, they started at the battery, and were ziptied to all kinds of things, including the speedo cable, then it went IN the frame out the rear and over the subframe (how did i miss this when the subframe was out?)
so at some point i mentioned the mystery wires, they started at the battery, and were ziptied to all kinds of things, including the speedo cable, then it went IN the frame out the rear and over the subframe (how did i miss this when the subframe was out?)
01-15-13, 06:26 PM
#56
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today i put the vacuum rack and coils on, and um i no like! its BUSY in there.
then i opened the wiring box, and have spaghetti... there are about 2.5 FD engine harnii in there, the FC dash harness, two FC battery harnesses, the S5 engine harness and part of the body harness!
once i sort out that crap the goal i think is to make a harness that goes from the FD ecu to the FD engine but plugs into the FC body harnesses. it must be easier than building the JC cosmo dash harness right?
oh and its technically supposed to be done today, so i loose, but its come a long way in a short time, so i'm pretty happy. although it is time to take a day and fix the flat in the Rx8, and do laundry and stuff like that
then i opened the wiring box, and have spaghetti... there are about 2.5 FD engine harnii in there, the FC dash harness, two FC battery harnesses, the S5 engine harness and part of the body harness!
once i sort out that crap the goal i think is to make a harness that goes from the FD ecu to the FD engine but plugs into the FC body harnesses. it must be easier than building the JC cosmo dash harness right?
oh and its technically supposed to be done today, so i loose, but its come a long way in a short time, so i'm pretty happy. although it is time to take a day and fix the flat in the Rx8, and do laundry and stuff like that
01-15-13, 07:02 PM
#57
so it didn't get done today ... pish-posh! you did a LOT of work in a relatively short time. i definitely tip my hat to you for what you're about to endure with the wiring.
totally random question, i know, but in what shape was your turbine housing? i'm just curious. i noticed what seemed to be a crack at the turbine inlet septum and was wondering if there were any on the inner housing.
totally random question, i know, but in what shape was your turbine housing? i'm just curious. i noticed what seemed to be a crack at the turbine inlet septum and was wondering if there were any on the inner housing.
01-16-13, 10:21 AM
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so it didn't get done today ... pish-posh! you did a LOT of work in a relatively short time. i definitely tip my hat to you for what you're about to endure with the wiring.
totally random question, i know, but in what shape was your turbine housing? i'm just curious. i noticed what seemed to be a crack at the turbine inlet septum and was wondering if there were any on the inner housing.
totally random question, i know, but in what shape was your turbine housing? i'm just curious. i noticed what seemed to be a crack at the turbine inlet septum and was wondering if there were any on the inner housing.
i'm only running an s4 because the manifold has an EGT port on it. i'm planning to use EGT as my boost limit, but also i can look at pre-turbo backpressure. it will be really neat to see what happens with that with different compressors.
i plan to test an H trim, V trim, and V trim with a T4 O exhaust wheel (this one = fast), and see what offers the best combo of preturbo backpressure vs power vs spool.
01-16-13, 10:21 AM
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01-17-13, 07:47 PM
#61
the turbine housing is pretty bad actually. the inlets are cracked. there's no way i could get a picture to turn out, but there are cracks internally and the surface where the turbine wheel rides has like a scale on it, you can tell the whole piece of iron has been too hot for too long.
i plan to test an H trim, V trim, and V trim with a T4 O exhaust wheel (this one = fast), and see what offers the best combo of preturbo backpressure vs power vs spool.
01-17-13, 11:36 PM
#62
Sat - 29*F high, -8*F low, WNW winds at 27mph
Sun - 2*F high, -16*F low, WNW winds at 8mph
Yeah, it sucks. That's why I spent my time in the 60*F LPG-heated large shed tearing apart my rear GSL axle for a rebuild. Much nicer than being outside pulling parts off a car for other people
Your build looks awesome by the way - sucks about the turbo. You made awesome progress though - keep it up!
Sun - 2*F high, -16*F low, WNW winds at 8mph
Yeah, it sucks. That's why I spent my time in the 60*F LPG-heated large shed tearing apart my rear GSL axle for a rebuild. Much nicer than being outside pulling parts off a car for other people
Your build looks awesome by the way - sucks about the turbo. You made awesome progress though - keep it up!
01-23-13, 11:25 AM
#63
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work continues, the good;
it was 67 degrees out the last few days.
i need to upload some pics, but i got a dash, swapped the S4 harness for the S5, and installed it. its in poor shape, but its better than nothing!
of all things the cluster is a 50k mile US S5 T2 unit....
lets see i plugged a battery in it, and was able to roll the driver winder down.
the bad news;
i spent 2 hours f-ing with the drivers door handle, and i adjusted it wrong, so i need to pull it apart AGAIN....
i found an Rx8 lower radiator hose, and it would fit perfectly, except its a different diameter.... it needs to come out of the engine, turn about 100 degrees, go to the passenger side about 6" then make another 90. i think i'm going to have to find two hoses with 90 degree bends and put a pipe in the center, to make it work :/ which means i need to BUY something, boo
i put the EGT probe in the exhaust manifold, and the manifold is installed, however i can't put the turbo in, until i figure out the oil drain. we did have an REW FC running before, and it had an oil drain, i just cannot find it, nor do i see any parts that would work, the FD drain is different, of course. turbo can't go on without it, and exhaust can't go on without turbo.
i also started to clean up the FD vacuum rack, which isn't so bad, but for some reason getting the harness to fit is being a real PITA. since i wanna run a stock ECU, and smog it, i need to have the CEL off, so i'm leaving all the solenoids there, even though some aren't going to be used except to turn off the CEL.
so i'm stuck in a few places :\
it was 67 degrees out the last few days.
i need to upload some pics, but i got a dash, swapped the S4 harness for the S5, and installed it. its in poor shape, but its better than nothing!
of all things the cluster is a 50k mile US S5 T2 unit....
lets see i plugged a battery in it, and was able to roll the driver winder down.
the bad news;
i spent 2 hours f-ing with the drivers door handle, and i adjusted it wrong, so i need to pull it apart AGAIN....
i found an Rx8 lower radiator hose, and it would fit perfectly, except its a different diameter.... it needs to come out of the engine, turn about 100 degrees, go to the passenger side about 6" then make another 90. i think i'm going to have to find two hoses with 90 degree bends and put a pipe in the center, to make it work :/ which means i need to BUY something, boo
i put the EGT probe in the exhaust manifold, and the manifold is installed, however i can't put the turbo in, until i figure out the oil drain. we did have an REW FC running before, and it had an oil drain, i just cannot find it, nor do i see any parts that would work, the FD drain is different, of course. turbo can't go on without it, and exhaust can't go on without turbo.
i also started to clean up the FD vacuum rack, which isn't so bad, but for some reason getting the harness to fit is being a real PITA. since i wanna run a stock ECU, and smog it, i need to have the CEL off, so i'm leaving all the solenoids there, even though some aren't going to be used except to turn off the CEL.
so i'm stuck in a few places :\
01-30-13, 02:15 PM
#65
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i've been meaning to post pics! since i'm a little stuck, i've spent more time cleaning the shop, than anything else, i didn't know there was floor under all the junk!
ok pics!
#1 is the interior before, i wiped it down with a rag and some simple green, then i had to put the S5 dash harness in the new dash. for some reason i don't have a picture of the dash installed?
the door handle got put back, again, and this time it works!
the next two pics, i found all the FD intercooler, and piping, so i mocked it up, since it doesn't fit with the radiator, its a no go.
ok pics!
#1 is the interior before, i wiped it down with a rag and some simple green, then i had to put the S5 dash harness in the new dash. for some reason i don't have a picture of the dash installed?
the door handle got put back, again, and this time it works!
the next two pics, i found all the FD intercooler, and piping, so i mocked it up, since it doesn't fit with the radiator, its a no go.
01-30-13, 02:37 PM
#66
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i had a Clokker moment, i looked in the FC interior parts bin, which was empty, except for a meter hood. when i was looking at it i noticed its not straight, WTF, what kind of sick twisted people made this car? the meter hood is straight, but it not, the window regulators came from the **** shop...
anyways turbo got installed, the oil feed line actually just fits, its using the stock FD line on the engine, to the FC line on the turbo. i bent it a tad, but its a nice surprise it fits. this allowed me to install the precat, since the second drive is to get a smog check, i kind of need it, and B i don't actually own a downpipe yet, although that is like step 2.
i still need an FC->FD oil drain, as the flanges are different, but i think i just need to cut, and use a hose. the S4 main part is the right length.
the next bit i found cleaning up, is the JC cosmo air pump adjuster bracket, which is neat, but turns out to hit the IC pipes.
actually speaking of, i found the swaybar brackets, so i put the front swaybar on, and of course it hits the IC pipes, so i had to rejigger those, mental note to self; make sure on a dare, you have less custom work!
anyways turbo got installed, the oil feed line actually just fits, its using the stock FD line on the engine, to the FC line on the turbo. i bent it a tad, but its a nice surprise it fits. this allowed me to install the precat, since the second drive is to get a smog check, i kind of need it, and B i don't actually own a downpipe yet, although that is like step 2.
i still need an FC->FD oil drain, as the flanges are different, but i think i just need to cut, and use a hose. the S4 main part is the right length.
the next bit i found cleaning up, is the JC cosmo air pump adjuster bracket, which is neat, but turns out to hit the IC pipes.
actually speaking of, i found the swaybar brackets, so i put the front swaybar on, and of course it hits the IC pipes, so i had to rejigger those, mental note to self; make sure on a dare, you have less custom work!
03-05-13, 12:43 PM
#67
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update; i got to a point where it was easier to clean the shop than work on the car, and then i bought another Rx8 cause it was super cheap.
it didn't help that the light over the car burned out, so i haven't touched it in weeks.
would you believe 130 day challenge?
it didn't help that the light over the car burned out, so i haven't touched it in weeks.
would you believe 130 day challenge?
03-11-13, 05:41 PM
#68
i was sitting at a light today and allowed my eyes to wander when lo and behold, the car in front of me wore the license plate ... PEEPERS. i chuckled. 
i figured i had to come home and check on your progress with this project, but i see your update from 6 days ago. the sickness that is rotary, in you, burns on. funny how "'cause it was so cheap" makes others with the sickness think of you as a humanitarian ... like one of those wildlife relocation activists or something.
so what's the plan for the new 8?
i figured i had to come home and check on your progress with this project, but i see your update from 6 days ago. the sickness that is rotary, in you, burns on. funny how "'cause it was so cheap" makes others with the sickness think of you as a humanitarian ... like one of those wildlife relocation activists or something. so what's the plan for the new 8?
03-12-13, 11:42 AM
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i did a 60k, and coils, with redline for the trans and diff. its mostly cleaned, i need to pull the seats and get under them, and do the windows.
it needs to have a couple tires swapped, they are new on the right side, so its running a NASCAR stagger, and then its for sale
it needs to have a couple tires swapped, they are new on the right side, so its running a NASCAR stagger, and then its for sale
06-21-13, 09:02 PM
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its back! it made noises today
06-28-13, 10:03 AM
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ir runs! quite nicely actually. i had to do a little relationship building. for some reason i wasn't getting fuel, but all the parts of the fuel system tested good on another car, so i sweet talked it, and patted it on the bum.
i also put the FD ecu in, and the turbo is back on.
i also put the FD ecu in, and the turbo is back on.
06-28-13, 10:22 AM
#73
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moar pics, the pics will get better now that it can move out of the deepest darkest corner of the shop
and why does changing the name of the photo make it upload?
the little harness is the FC to FD TPS harness, i'm using an S5 harness and about half the engine side plugs in, i've made little adapters for the CAS, TPS, IAT, and trailing ignitor.
and why does changing the name of the photo make it upload?
the little harness is the FC to FD TPS harness, i'm using an S5 harness and about half the engine side plugs in, i've made little adapters for the CAS, TPS, IAT, and trailing ignitor.
06-30-13, 09:14 PM
#74
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added an electric fan, think it'll be enough?
i also parked it on the wall, takes up less space
i also parked it on the wall, takes up less space
07-03-13, 10:41 PM
#75
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well today i adjusted the TPS, which sucks on an FD. they want you to check voltages at the ECU, which means you need probes that fit in the ecu, and then it still wasn't happy, so i had to bump it...
other than that i organized all the junk that needs to go back on after i gets painted.
we're thinking whale shark
other than that i organized all the junk that needs to go back on after i gets painted.
we're thinking whale shark