I am just waiting on a fitting for the fuel return line in the tank before I can start the fitment of it. but short answer to your question is no. I will need to cut the sides of the swirl pot out inside the tank for them to fit... Some tin snips should do the job... As long as I don't run any less than 20L at a time it should be fine! The car had two 450s in there already. But needed to replace them with e85 capable pumps..

 

Well here it is! The dual pumps to fit the FC tank pretty happy with it.. However there is one issue with the 460 walbros...



So because of the bottoms of the pumps are huge for some reason they don't fit into the swirl pot.. So am forced to cut out one side so it fits...



And yes it does fit! So at the moment I am just putting the fuel level sender on and getting the wiring through the top and that should be it!

 

Here it is! finished! All wired up and fuel level sender attached. I didn't add in the level warning light as i never run below 20L any ways..


Filters on


Back side of the hanger.. We have directed the return return away from the internal swirl pot so it doesn't dump -8 worth of hot fuel in there!


Yep.. it was a bit of a tight fit getting it all in there.. But it's possible.. Just wiggle it a little bit, and in she went!


Her final resting place... Hopefully I wont need to take this out again for a while.

 

Started to do the fuel return lines to the FPR and finshed that part. REALLY not happy with PROFLOW with the primary fuel rail.. I have sent photo's and asked for help and seem to have gotten the cold shoulder. This kit DOES NOT FIT the Series 5 intake manifold. Please get a AEROFLOW if you get a kit like this. I have had to machine it to fit.




With the fuel return done from the lines to the FPR it was time to start the IN. I ended up running out of fittings and need two more -8 30degree fittings to finish this part off...

 

 

Stop hogging the 2nd Gen Build thread :P

Good to see you making great progress mate! You have been busy!

 

Thanks mate, there is still a long way to go for her to be track ready!

haha, yes and this is only the start of it!! This is just for E85 and getting ready for engineering!!! Still need to wire Microtech, wire fuel pumps etc etc, the get hareness, seats half cage and more.. ugh
As soon as its ready for Rego, more work needs to be done to get it track ready!!!!

BUT aiming for a December finish date with her running 24psi

 

Sigh... Bins are out... Unfortunately they need to come out and can't go back in with the half cage... Soon as the half cage is in, it will never go back in the car unless i chop them up, which i would rather not do, and let them go to someone else that would like them..

Pretty much everything is out of the boot now, and I have **** everywhere!!!!!!!!!

 

On another note! I have once again did a backflip on the turbo!!!

The last most expensive thing has now been ordered! And should be able to pick it up tomorrow or thursday.. After doing some talking with the local GCG Turbochargers I was originally looking at the GTX3584RS (1000hp) however would need to modify my exhaust manifold and it would ended up costing way more than i wanted to budget for this.. So they did an unreal price and are able to do a Frankenstein turbo for me. Basically they are going to get a GTX3582R T4 rear housing in the 1.06 and CNC machine it to fit the GTX3584RS, meaning it will have a T4 1.06 rear instead of the VBand entry of 1.01 or 1.21 - this should still have enough for an easy 700hp... with the spool of a GTX3582R...

I am keen to see how this puppy will perform.. I have not seen this style or type of setup on a 13b turbo as yet...

Also noting that the front A/R is a 0.72 not a 0.70 that you would see on a normal GTX3582R.

GTX3582R - 66mm inducer 82mm exducer .70 AR
GTX3584RS - 67mm inducer 84mm exducer .72 AR
So basically its a highflowed GTX3582R




GTX3584RS



GTX3582R


GTX3584RS

GTX3582R

As you can see with the GAS Flow pressure ratio, spool from the 1.06 should be interesting. It should come on pretty quickly, and have slight more top end than the 1.01 of that of the GTX3584RS's normal rear. And also by looking at that graph it might come on boost sooner aswell - but lets see.

 

My Bald Eagle Turbski arrived today!

 

Also got a new CAS cover from my main rotary man! XtremeAutoParts



Also upgraded the intake adapter to a 3" instead of the 2.5" and with the AIS on the bottom instead of it being on the top side.



Can't see it in this photo, but I also got rid of the Greddy oil stool aswell, since i don't need it anymore.

 

Comparing new with old... GTX3584RS (with 1.06 rear) v T66 (with 1.32 rear) be-leave it or not, but the GTX flows about 400hp more :S



The size difference between the exhaust housings is huge!




Here is a great shot of the size difference!

 

Of course I had to see what it looked like on Its a physically smaller sized turbo so it has so much more room now! If i wanted to run the air intake, and intercooler pipe I can, it matches with ease! But I will change the intercooler pipe to 2.75 or 3"






I have now taken the rear housing off, and the exhaust manifold and they will go to my mates shop to get ceramic coated!

On the other hand I started to finish off the fuel system, now I just need to get longer bolts and nuts for the under body to hold the lines in place.. So now the turbo has arrived, I need to start pulling my finger out and start finishing these things off! Soon as that's done, its getting stuck into the Microtech wiring!

 

Alright! Some progress today on the fuel system. It is basically done....

Here are the lines under the car, 1x -10 (feed) 1x -8 (return) and in the middle is the battery cable!

Just one more thing I need to do is to connect a short half a meter -10 from the filter to a spot where i have just under the sub frame to disconnect if i ever need to take the diff out.. Instead of having to pull the entire fuel lines out to get the diff out :S
I couldn't 100% finish today as I need 2 more -10 fittings and that's it! its time to move on!

 

While I was at it and couldn't finish the fuel system completely, next on the list was oil catch can and hose fittings to the oil filler neck...

Pretty happy how its turned out, however a little worried that the can sits below the neck, however above the motor...






So basically after this, the turbo exhaust housing and exhaust manifold should be done next week, so I should be able to bolt the turbo up and start routing the oil in/return, and water in/return!

Soon as that is done I can finally move onto pretty much the last part of all this, which I think will take the most time, which is the Microtech wiring! Progress!!!

 

Just got back Exhaust Manifold, and Turbo Exhaust housing have now been ceramic coated. Should have noticeable heat difference in the bay now!

 

Yay the LAST fuel hose done! Thank god for that!



I was having issues with the fitting the fuel filter and finding space for this 100 micron filter to fit anyway along the line.. this was the best spot I could find for it.



Originally I had it above the rear IRS arm, but as it lowered it was touching the fittings and squishing it.. So I was forced to fit it here, there is still plenty of clearance.



EGT sensors fit mint! Also as you can see on my lower intake manifold I have taken the block off to get a -6 fitting for the water feed for the turbo!



Now that I have finished the fuel system I can now officially move onto the wiring! The part I have been putting off the longest, however this is one of the last things and most time consuming things left to do.

The Fuel Pressure and Oil Pressure senors wiring have been done.



The main loom, just getting everything into position!

 

Changed my wiring to the Pressure Senors and changed from tape on the ends to heat shink looks so much better. The rest of my engine loom will be like this.




I also got some brand spanking OEM pedals that came today! Fitted to the car with ease. No point showing any photos as you all know what they look like!




I am waiting for the last of the oil and water fittings for the turbo. Once they arrive next week I should be able install the turbo next week hopefully!!!!

It's funny after doing all this myself, I have gone over and ordered either too many fittings or the wrong fitting stupidly.. I have 11 too that are no use to me!!! hahaha oh well

 

Checking out my Engine to Manifold gaskets they are gone! I got them replaced with steal ones.


OMP block off was leaking a little. Before it look like a rough cut of Aluminum cut off.. it was rubbish..



Got a proper cut off from Xtreme Auto Parts who is always helping me out with parts!


Water in for the turbo done.


Oil Drain, Pretty happy how it finished up.



One side of the water in, and the Oil Drain


EGTs sensors are installed.


Inside the pipe. Mind the scratches.


It was a bit of a PITA to get the oil drain in place where I wanted it, but worked out in the end.

 

Killing me on style points mate, Looks awesome with the braided lines and shiny turbo! Far out you work fast! Going to be a monster once it's running!!

Hey how much did the pedals set you back? Mine are flogged out and need a new set as well

 

Ha. Says the guy with a S15 dash! :P

Well, to be honest I am not 100% happy with it.. But given the limited tools I have, I have to work off what I got and the knowledge that I gained from my last build.

But saying that, hopefully everything should be right, I triple check everything, so just hope there is no leaks or issues!!! But yeah, It will be! I just hope my motor sticks together until end of next year! but who knows!

They cost $70 including postage from ebay Japan. Pedals

 

Just came across this thread somehow, looks great man! I'm getting started on my Time Attack build soon as well. Just getting some customer stuff out of the way.

 

Hahaha You got me there... finally got that ****** working. But you have the shiny bits! LOL :P

You're in the thick of it now but you are doing everything right (double, triple checks) so it'll be fine. Shame you aren't closer, I'd bring a 6 pack round and help turn some spanners... Like you said, pull from the experience from your last build get it to turn key stage Can't wait to hear that turbo sing!!

Thanks for the link on the pedals. I'll order them ASAP.

 

Major props to you, man. I have thoroughly enjoyed your thread thus far. I'm looking forward to the rest of the ride.

Also, I really like that fuel tank cover. I've been stressing over what to do with mine for the last few weeks, and now you have REALLY have me thinking about getting one.

 

@nismo_bill thanks mate, still a long way to go! After getting this side of things done and the car with registration, hopefully if the car sticks together and I dont go blowing gearbox, diff or motor I can then start focusing on aero package for the car. Nothing crazy, but will be getting RE-Amemiya Pro defuser, Super-G Wing and Bonnet Still need to work out other bits and pieces like a front spliter etc.

@Reckless_Panda, Had for sure mate, there is a few things I need still need to finish, then I need a few more planing things on wiring then I can hook in. Also I have my eyes on some Sparco Grid II and when they arrive and wiring is done, it will be off to get the cage and seats bolted in!
And yeah, it is.. I seem to be away from everyone :\ But you should make a trip down for the World Time Attack in Sydney in October

@diabolical1 Thanks man.. I started to think no one really cared or liked my content!!! haha appreciate it!! Yeah hit up Stu Kelly Motorsports... He can custom make it to how you like. Also keep in mind Walbro have just released the walbro 525 E85 pump too! Single one is able to supply up to 700 E85 Hp... So thats huge! If this was available before I put the two 460s in I would of gone a single, but have a feeling it still wouldn't be enough.. it has enough now!