Exhaust sleeve installation





Notched the housings to mate up with the bridge port


Apex seal glue time


Cutting down side seals

 

Assembly









Transmission on and tightening down bell housing bolts and installing starter


Ready to go in the car

 

Installation



Bolted in, ready for plumbing and wiring!



Need to install the driveshaft, hook up the exhaust, and do a couple other things with the transmission (shifter, speedo cable, etc). Then, connect all the wiring in the engine bay, make some stainless AN lines for fuel and oil cooler lines....soon time to fire it up for the first time.

 

Engine bay is almost done - a few miscellaneous things to do tonight.



March:
Tonight:
- Transmission wiring
- Vacuum lines for boost controller and wastegate
- Tidying up wiring/hoses, tying things back
- Installing battery tray
- Extending wiring for fan harness (it's soooo close)
- Sand one more spot on the body and prime it

Tomorrow night:
- Bleed brakes
- Set up the ECU for new injectors, aux outputs, boost control solenoid
- First start up!
- Clean up the car - interior and exterior - reinstall all interior trim


April:
- New thermostat installation (it gets here Friday)
- Custom air intake (in progress)
- Make new lexan headlight covers (2 hours) (IN PROGRESS)
- Have it vinyl wrapped (3 - 4 days)
- Install RE-Amemiya front bumper
- Install S5 tails (30 min)
- Install S5 rear bumper and moldings (a couple hours)
- Reinstall rear window in the top - I have decided to get an auto glass guy to do this while it's being vinyl wrapped
- Rebuild passengers seat (2 hours)
- Install seats (1 hour)
- Alignment (booked for April 11)
- Install rear diffuser and side skirts (4 hours)

 

Looking great! Not much left to do now. Like the color theme going on too, reminds me of my GXL's engine bay.

 

Yup, she goes to the vinyl shop likely Friday. Soooooo close!

 

Nice progress waiting to see it wrapped my self .

 

If anything ever happens to this build where it doesn't work out. I'll buy that turbo kit off you today .

 

Haha yeah they're hard to find. I think I might be buried with it LOL

 

No video yet, but did some more work last night:




Air intake is done, transmission wired, vacuum lines run (just need a tee), fan is wired, battery tray installed.

Updated to-do:
March:
Tonight:
- Bleed brakes & install new Hawk brake pads
- Set up the ECU for new injectors, aux outputs, boost control solenoid
- First start up!
- Clean up the car - interior and exterior - reinstall all interior trim


April:
- New thermostat installation (it gets here Friday)
- Make new lexan headlight covers (2 hours) (IN PROGRESS)
- Have it vinyl wrapped (3 - 4 days)
- Install RE-Amemiya front bumper
- Install S5 tails (30 min)
- Install S5 rear bumper and moldings (a couple hours)
- Reinstall rear window in the top - I have decided to get an auto glass guy to do this while it's being vinyl wrapped
- Rebuild passengers seat (2 hours)
- Install seats (1 hour)
- Alignment (booked for April 11)
- Install rear diffuser and side skirts (4 hours)

 

Update from this weekend:

- Tried to start it Thursday night, had a short at the starter
- Fixed that on Friday night, got the car started, big exhaust leak, oil leak at the oil cooler, and the timing was off, but it started.
- Saturday - fixed the oil leak at the oil cooler, got the e-fan working, fixed the timing, fixed the water temp sensor, it runs - mostly - need to change some stuff in the ECU to get it to run right and idle.
- Sunday - Took off the downpipe to fix the exhaust leak (the EGT probe wasn't sealing right so I removed it) and made new gaskets for it. Also re-installed the Bypass Air Control valve, which helps control the idle and re-wired something on the fan, put on brake pads on one corner of the car

- Tonight's plan: Re-wire high speed on the fan, see if we can get the ECU dialed in a bit, maybe start vinyl wrapping


Updated to-do:

- Finish setting up the ECU
- Finish installing brake pads
- Clean up the car - interior and exterior - reinstall all interior trim
- Finish new lexan headlight covers
- Have it vinyl wrapped
- Install RE-Amemiya front bumper
- Install S5 tails
- Install S5 rear bumper and moldings
- Reinstall rear window in the top - I have decided to get an auto glass guy to do this while it's being vinyl wrapped
- Rebuild passengers seat
- Install seats
- Alignment (booked for April 11)
- Install rear diffuser and side skirts (4 hours)

 

I've hit a bit of a roadblock, still can't get it to run right, so I'm having to seek additional help. The ECU is my nemesis, so I have moved on to finishing every other aspect of the project and tackling it last.

 

Here's how she sits now:


Had to put the idle valve back on


Some body parts showed up!


I got a little distracted for 2 weeks in North Carolina.


Gratuitous shots of new body parts and mock up of the side skirts for fitment - needs a little adjustment but very very close.






Next I need to figure out if my timing marks are correct, long story. Then get the ECU set up so the car will run right.

To do:
- Re-wire high speed on the fan
- Figure out timing
- Fix exhaust leak at midpipe
- Figure out ECU tuning
- Fit the sideskirts, then prime them and get ready for wrap
- Finish installing brake pads
- Clean up the car - interior and exterior - reinstall all interior trim
- Finish new lexan headlight covers
- Have it vinyl wrapped
- Install RE-Amemiya front bumper
- Install S5 tails
- Install S5 rear bumper and moldings
- Reinstall rear window in the top - I have decided to get an auto glass guy to do this while it's being vinyl wrapped
- Finish reassembling passengers seat
- Install seats
- Alignment
- Install rear diffuser and side skirts

 

So good!!!

 

Ordered the new pump for the intercooler system...trying to get a few parts together to finish some things.

However..........IT RUNS!!!!!!! thewird worked some black magic on the standalone while he was down for a tuning trip and it happily idles. Timing is bang on.

We did find out the water temp sensor that feeds the ECU isn't working right, reading too low, so I have a new one ready to go in, as well as a new coolant level sensor and one for the water temp gauge.

Going to take the rad back out this weekend and start putting in the upgrades to the intercooler system. Also need to seal up the fuel sending unit - had to take out the pump because I wasn't getting fuel for some weird reason, but then it started working. I found a second fuel pump on the feed line that wasn't hooked up, so I'm taking that out while I'm at it. Bought a new gasket to seal everything up and finish that job.

 

Forgot to mention, I also bought a brand new set of OMP lines and those will be going on the car shortly too.

 

Got some goodies from Atkins!
New OMP lines, new coolant temp sensor, new water temp gauge sensor, and new coolant level sensor, new gas tank sending unit gasket and other odds and ends.




Was looking under the car and found another fuel pump plumbed in to the feed line from the tank - wiring wasn't hooked to anything. Since I have upgraded to a Walbro 255, I removed this over the weekend and routed the line straight from the tank. Was part of the Cartech turbo kit.



Got some upgrades going to the air to water intercooler setup - a Bosch cobra pump and a Cobra heat exchanger are going into the car - got some of the mounting done for this on Saturday, going to finish it up this week and clean up the welds, etc.








Next I'm upgrading the ground wire from the block to the firewall, checking the grounds at the strut tower, re-installing the UIM and fuel rails, installing the intercooler pump and all the hosing, and try running it again.

 

New OMP lines installed!


New Bell Housing > Firewall ground, and fixed the ECU ground


Finished mounting the Intercooler heat exchanger




Mounted the pump, working on plumbing and wiring...

 

AAAAAND bought a new project/toy:

 

I was able to get back at this project again on the weekend. Cleaned up a bunch of wiring under the dash and took out a lot of unnecessary stuff, many feet of junk wire, and relocated some wiring. My switches for the intercooler pump and fog lights seem to be working, so that's good.

Now, I need to re-think the feed line for the intercooler pump and put it on the bottom side of the tank - it was on the top before with a tube down to the bottom but the new pump seems to want it to be gravity fed.

 

nice work

 

Ordered up a new tank for my intercooler system - going to rig it up like a mini old school ice box.


Hoping it'll arrive next week with the other fittings I ordered to customize it. Putting a ball valve drain on it and everything.

This will be replacing the plastic overflow tank that is being used for the intercooler reservoir now.

 

It MOVED! It drove under its own power for the first time in 3 years!!!!

 

How was it? What did you love; what did you hate?

 

What model of car was your E-fan off of? seem like is was good fit with a little cutting.