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ILLEGAL
29-10-2010, 09:10 AM
First off thanks for viewing my build up of my 7G vr4.

video link of my first atempt of the single turbo V6 is here...
http://www.youtube.com/watch?v=B-_iNcFWxYY

im still in the prosess of the second atempt of this conversion more on that later, lets get into the nitty gritty.

first of ill let you know how this came about..... I tried to get out of the "boy racer" scene around 2006-2007 by selling all my mitsubishi's and getting a BMW. it was the E32 1988 750iL model. so i was okay with my cruising tank.. untill.. my little brother bought a 88 vr4 with a T3/T4 in it with a few other mods. yep the boost bug bit, and it bit me hard,

http://i672.photobucket.com/albums/vv88/2ILLEGAL/Bmdubzkit.jpg

flicked the BMW for soo cheap you wouldnt believe it! "THE PLAN" is to buy a good car (read Mitsubishi) so i could participate in Drag racing and the 4&ROTARY NATIONALS and be running mid-low 12's for under 8K.. i knew of a 7G vr4 in CHCH running 12s, with factory turbos his record (New Zealand quickest 6A12 powered Galant) is here on you tube....
http://www.youtube.com/watch?v=XPM4jVNe0Pw (the video title has been modified for reasons that will become clear soon)...Sooo.. with my little pocket of green folding stuff i managed to purchase a 1995 E84A Galant VR4 with 160,000kms, for only NZ$2000.00 this came with a cat back 3" Fijitsubo and 17" advanti wheels, a clean inside and tidy outside. 2.0L turbo (twin) and 4WD. so i had my platform. and a few goals, i wanted a 12, and to beat this 6A12 Galant record!

http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image035.jpg http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image035.jpg

the very first thing i done was add a bit more boost. upto 15psi it was then! then a oil change.. well i done it twice in the same day, just to flush it out good. and removed that spoiler!

http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image044.jpg

the next mod i done (the day after buying it) was a intercooler. it was purchased from SCARLES measuring 600x300x75mm with 3" in/out pipes, this fitted okay with only little cutting of the factory bumper and a few straps made to hold it. also during that week i fitted a SCARLES SSQV blow off valve to the factory pipe using a adaptor. and in this state i ran my first 1/4 mile. factory with only the cat-back 3", intercooler and 15psi, i managed a 13.83. so now i have some sort of base run under my belt, its time to go forward with my project.

something i noticed was the temp wasnt being controlled as well as i hoped venturing into the hot zone abit further than i liked, so into the mix i added a 45mm aluminium radiator from SCARLES. this was a bolt in job with the only change from factory being the radiator fans and one of the top mounts being moved over to the next set of bolt holes, it was like Mr Mitzy knew i was going to get this radiator and made the bolt mounts there for me.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image022.jpg http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image081.jpg

so after a few more events and abit more learning BUT without limmiter launching, i managed to get my PB down to a respectable 13.60 with not much in terms of mods. remember that when this car was new, there was no 10sce club! if you could cut a 13 you were quick!.... but its now its late 2008, and a 13.6x just wasnt going to do it! so onto the next step in development...


... shopping list:

*1 x TD05HR from a mates proven evo4 powered mirage (the turbo poped his motor so it work enuf for me).
*1 x rear turbo manifold to bolt onto the front head. (required to make joiner pipe shorter).
*1 x Apexi old school AFC (the 5 rotary nob version).
*6 x 390cc injectors from a Lancer GSR, (cleaned and flow tested).
*Walbro 255L fuel pump. (intank and hot wired)
*new shiny 2.5" intercooler pipes.
*new 2.5" silicon joiner pipes.
*EXEDY HD clutch kit (yep @180,000kms it was slipping)


the installation was a long process carried out in my garage with help from a mate to do some welding.. these are a few random shots..

last look at the twin setup..
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image081.jpg


empty/striped engine bay...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image023.jpg

shot of the front head with a rear manifold off it...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image021.jpg

mocking up the cooler pipes...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image040.jpg

oldx1 versus TD05HR...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image019.jpg

new clutch kit...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image026.jpg

GSR 390cc (left) Vs factory 275cc (right)...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image086.jpg

apexi AFC...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image088.jpg

TD05HR on its own...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image008.jpg

factory AFM pipe mod'd (rangi fix)...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image053.jpg

new manifold getting made up...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image075.jpg http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image084-1.jpg

http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image076.jpg http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image082-1.jpg

after its made wrap it up...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image25.jpg

then put all in together as one piece again... (note the Legnum brace)
http://i672.photobucket.com/albums/vv88/2ILLEGAL/Image35.jpg


so that took all of winter 2009 to be completed. taking apart stuff, buying stuff and making stuff.. but i thought it was a step in the right direction.. so NSDW (night speed drag wars, summer) was cumming up and i was ready.. i wanted to get my first 12sec pass... but... it was not to be. managed to chop a whole 0.5 out of my time, its a huge chunk of time off, but something wasnt correct, after asking a few people what a metalic rattle sound was comming from the turbo? it was diagnosed as the wastegate not closing 100%.. i took the turbo out to find the gate open quite abit.. so back to SCARLES to get a new external gate, 50mm should be the go for this situation?LOL... plumbed it in, and straight away it was good. boost came on solid as i expected, and a loud roar once on full boost.
http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00069.jpg


next event was the big1.. 4&ROTARY nationals, in Auckland. this was going to be the day.. the day i got my first 12sec pass!! (i hope so any way)

the video of that event is here for you to watch...
http://www.youtube.com/watch?v=3OQq1e0KfFI&feature=related

so it was a bad start to the day with no practice runs (not good for DYO racing) and wet weather all morning, i thought i might have spun up toooo much with it just finished raining, and better boost thanks to the fixed wastegate. but i bogged down and the forester got a whole 4-5 car lenghts in front of me before i started to make any boost! so a 14.03for the first pass, at least there was no way i was going to "breakout" and i was lucky to get a win flying past him at only 1/4 track!

but thats wasnt the 12sec run i needed to make me happy.

i managed to work my way through the field running low 13's... i made it all the way through to the semi finals and was expecting a bye run considering the other 2 competitors had byes earlier that day.. it wasn't to be.. i lucked out and was running next to a built s14 with a large turbo and M/T drag radials to match! She (yep a female) had been running 12.7 consistent all day and i knew i had to be right on the money when it came to my dial-in so seeing as i hadnt run a 12 all day but got a 13.00, i thought i would be safe dailing a 12.95.. it seem with the extra urge to beat the faster car i "broke out" running a 12.94!... .94! yep .01 too fast for me to get thru too the 4&R nats DYO final but i got my first 12!! either way i was buzzing!! it was a great day but....

upon inspection of my wastegate installation, i found a few pin hole sized holes all over my welding job. so i touched this up as best as i could with the limited space and it felt like a further improvement on what i thought was good.. following the Nationals, NSDW round2 was held.. and on this night it was nice and cool, and had been a hot summers day so the track was perfectly preped by the sun all day. my car was leak free, so i thought.. never mind it was running good enuf! most of the night i was running 12.8 i got a few 12.9's but never got back to the 13's! it was mint.. lost a race, just! in the DYO racing so was out of points racing for the night. there was grudge racing at the end of the night so i stayed around for that,. the car got a good cool down before the grudge run and it finallly came time to hit the strip again, i found myself sitting next to the "Green Brothers" white RX-323.. he done a burn out while i crept onto the staging lights. i usally stage shallow so i can blast off on the last yellow. i knew he was going to win but i didnt want it to be easy for him.. after both staging lights were up i hit the limmiter, yellow yellow and poped the clutch out on the last yellow, never saw the red light so i continued, he was in spitting distance all the way to the end and i knew he was a 11sec car so i knew i was quick on that pass..... how quick??? ...comming down the return lane with the window open and helmet off i could hear the voice's of my mates and brother.. hmm whats the noise about i thought to my self.. ??? nah i couldnt have?? did i?? i got my slip BUT didnt look.. i continued into the pits where i was meet from the boys who ran down with massive smiles on there faces arms in the air (few fist pumps, LOL).. i could hear one of them say "you done it!" i was like "what?".. "you got the record" NAH!! didnt believe them so i had to look at the slip... OMG! i ran a record breaking 12.607 to claim New Zealands quickest 6A12 powered Galant. the previous record was ran 5-6 years earlier in CHCH by the well known AKO a.k.a MARKY who ran a 12.64 in a standard turbo'd 7G. it had been standing for 5-6 years! felt sorry for [VR4GZM] who busted his bottom end that night. but was a good one for me.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/slipscanedited-1.jpg



so that was my biggest night in drag racing too date. down in CHCH the next day a few others tried to get it but only managing 13's, so todate, i still claim New Zealands quickest 6A12 powered Galant. but im not finished there.....



the beginnings of PART TWO:

so the way the turbo was mounted made it hard to service the turbo and wastegate, it also made it impossible to completely seal the wastegates mounting plate, so it was still leaking, just (but it was leaking)... so in my head the only option to fix the problem area was to remount the turbo over the gear box where it will be accessible and the wastegate can be plumbed into apart of the joiner pipe where it can be welded up properly!

seeing i was going to remount the turbo right in your face as you open the bonnet, i thought i would for a turbo with physical presents. after shopping around for awhile (from March-August) i decided i wanted a turbo bigger than T3/T4 but smaller than a GT40.. so a GT35 fitted the bill nicely. but... i had a budget of under $700 so it had to be fake a.k.a China turbo.. i stumbled across a brand named TRS (turbo research) who made turbos (CNR Racing) who are planning to have a shop/stall at the USA SEMA show this November. they also sponser the international drift series in Asia (same event Fanga Dan has his Commy running in) so it has abit of money behind it. found out there is a guy on trademe with a few of these turbos for sale, got in touch with him a purchased one.. TD06 25G.. it has a nice big A/R.70 compressor housing which is all i was after! i just want the look.. if it go's pop i can put better internals there! heres a few pix..
http://i672.photobucket.com/albums/vv88/2ILLEGAL/td06angle.jpg

and next too the TD05HR (Evo4)...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00181.jpg http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00184.jpg

afew other upgrades/mods i have gathered over this winter are:

*MAPECU2 (installed still running KVF learn mode)
*Cooling Mist Water/meth injection system full kit (running with 380cc injector)
*LC-1 wideband o2 sensor with digital display/gauge.
http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00005.jpg
http://i672.photobucket.com/albums/vv88/2ILLEGAL/coolingmist.jpg

so this is where im at now...
http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00182.jpg

i have my steam pipe and new TD06 3 bolt flanges ready for fab, the car is at the engineers, and while im at it we will be making a new intake/plenum to mount the throttle body on the other side of the engine bay to free up enuf room to get the turbo above the gearbox. cant wait to update this thread! wont be long i hope! was planning on getting to the first round of NSDW on the 5th of Nov?? but im not sure if thats going to happen (1week to go??) so im aiming to be at the 4&ROTA Nats'11.

thanks agian for checking out my build i will be updating this once the cars is running again. with pix and vids (as i do).

look forward to becoming a paid member and meeting some of you/Camera

pbaron
29-10-2010, 10:02 AM
What a good read, well done dude.

Fully
31-10-2010, 02:06 AM
WD Richard that was a good read =)

MarkSanne
31-10-2010, 01:08 PM
Great read & results! Keep it going and keep posting updates :)

Oblivion
01-11-2010, 10:00 AM
Interesting to read and congratulations on that record :)

ILLEGAL
19-11-2010, 07:38 AM
okay so today i went to check up on progress of my car and they were almost finished with the plenum.

note: the "plans" AKA. internet pic's of other builds in the back ground of some of the photo's.

they managed to route out the square edges on each intake inside the plenum... yeh no trumpets but more of a port job.. and instead of welding around the out side of the join between the new box section and the oem intake, they welded on the inside of each runner, then grinded/routed it back... it is alot boxier than Nicks but it will do the trick for now.. surely wont be hard to sell if i want a better flowing item?

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00238.jpg ..plenum ported intakes lookin thru T/B

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00237.jpg ..plenum angled view

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00246.jpg ..plenum side view #1

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00239.jpg ..plenum side view #2

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00247.jpg ..plenum end tank view


also had to remove the solid part of the power steering that was in the way of where the throttle body will now sit.. going to try this hose with hose clamps first before getting hydralink to make a real P/S hose up for me. the hose is transmisson hose so should hold up.. not sure if the clamps will though?
http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00250.jpg ..power steering hose

so with abit of luck this should be back on the come the end of monday.. to do on the plenum is a few tig welds around the outside of the join between the new box and oem intake, just for added strength.. and also a block with the brake vacuume hose tail and 5 little tails for the ecu map sensor, boost guage, fuel regulator, BOV and water injection hobbs switch. i might get 6 on there just as a spare for now.. wastegate will be controlled by the "P" tail on the throttle body it has +psi but no vac so should work? just glad to see it move forward.

i also purchased 2x 3" U-bends today for the exhaust off the back of the turbo.. i hope a 3" fits back there. im sure its nothing a hammer cant fix though?

Gly
19-11-2010, 08:59 AM
nice bit of progress there,

will be interesting to see how that turbo performs,

ILLEGAL
19-11-2010, 09:21 AM
/duh .. i hope it spins.. /duh

maori_by_nature
19-11-2010, 10:06 AM
personally i like this video of your car... http://www.youtube.com/watch?v=oVqacgxJJaM&feature=related

ILLEGAL
23-11-2010, 07:55 AM
not far off RE-START now.. plenum is finished but can do with a sand and polish once i get around to it. the steam pipe manifolds are finished apart from the wastegate pipes. i will heat wrap everything again once i find the time to. so heres the updated photo's of the car today.... sorry about the photo quality, this was the first time using this camera and didnt realise i had to stand still for a hour while it takes a photo :!:


here we have the new gaskets i made to replace the damaged items i had.. i used ACL gasket paper for the job, and im happy how they turned out. may need to trim them still once i get to fit them on the car.



http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0074.jpg starting on new plenum gaskets



http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0076.jpg half finished plenum gaskets



http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0078.jpg finished plenum gaskets



and here are a few random shots of the engine bay, first off the throttle body with the ISC removed and blocked off. it sits nice and square to the motor which looks real nice in person.. also have 5 small nipples on the rear of the plenum and a large nipple for the brake, and a 6th little nipple on the front for the BOV.



http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0046.jpg throttle body without ISC

http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0048.jpg plenum with nipples



and here is photo's of the turbo on the steam pipe manifolds.. note i need to spin the turbo which isnt a major at all with these turbos as they have true 360 rotation like a circ clip type turbo, and the wastegate plumbing isnt there either.



http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0060.jpg close up of TD06 25G on manifold

http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0059.jpg TD06 25G on manifold



now we (engineer and I) think we know why it kept cracking the last joiner pipes/manifold. its because only the manifolds were supporting the turbo, wastegate and exhaust on its own with no braces!! (my badd!) yep i over looked that little detail and cost me a little bit, but i wouldnt be where i am today if i never made that mistake. not wanting to have the same issues with this setup ive included flanges in the manifold (like Nicks) for abot of give when heat is applied,and a brace from the gearbox upto a bolt on the turbo flange at the turbos exhaust housing.. so this should hold up the turbo and exhaust so no bendy/cracky problems pop up?

so not far at all.. these were photos taken at 11am this morning so im guessing the wastegate is done and its just the 3" exhaust to be made and joined to the 3" under the car. oh yeh, then my part.. putting it back together again new heat wrap and gaskets , hoses and intercooler pipes.. and the biggest pain in the butt the AFM!!! grrr!

ILLEGAL
24-11-2010, 07:05 AM
engine bay photo's with turbo on the manifold :-o plus it fits under the bonnet!!!

http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0042.jpg wide view of the TD06 25G on its manifold, just starting to fit the 50mm wastegate.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/PICT0044.jpg wide view of the TD06 25G head on view.

BEG4ME
24-11-2010, 10:23 AM
So far this build has been fuk1n awesome man. Just one little thing. You may want more than one brace on that turbo aye (It's huge! Haha). Maybe from the engine valley to the top to tie it in. Kinda got the same problem you had with pipe cracks when i slapped a turbo on my mini chopper. Keep up the good work man.

ILLEGAL
24-11-2010, 10:58 AM
thanks mate ill look into that tomorrow (aswell as load that payment for bumper) and suggest it to the engineer, although i did mention it previously to him, but he's happy that just supporting the turbo from bouncing up and down will be enough, as that was the only movement it could have done. if we place a brace from the valley it will only stop movement left to right? which is covered by the manifolds themselfs? Also the steam pipe is alot thicker than the mild pipe the cracked from the weight of the previous TD05hr and to be honest, i think the new turbo is the same weight if not lighter because the TD05hr housing is bulkier than the TD06 (i havent weight them) but i will bring the issue back up with him.

sorry, forgot to mention the brace is 5mm thick

Siamblue
24-11-2010, 02:54 PM
Brilliant read mate, After the small turbos what is the next weakest link in the line of these cars? obviously these engines are almost bullet proof, just i am a novice on these cars as all my knowledge is in Volvos, my next car is going to be a Leggy :)


Gary

LudviG
24-11-2010, 04:03 PM
Love this project. Keep up the good work!

elnevio
24-11-2010, 05:59 PM
Brilliant read mate, After the small turbos what is the next weakest link in the line of these cars? obviously these engines are almost bullet proof, just i am a novice on these cars as all my knowledge is in Volvos, my next car is going to be a Leggy :)


Gary

Gary, Illegal's car is a 7G (seventh generation) Galant with a 6A12T engine, whereas most VR-4s on here are 8G ones with the 6A13TT. While some principals are pretty much the same, they are completely different cars, as the 8G was a new car from the ground up. There was no estate version of the 7G, sadly. Anyway, lower suspension arms are a known problem area, although many were replaced under recall, but a failure usually means wheel getting pushed up into the wing! Otherwise, shoddy maintenance and low-quality fluids will be detrimental to the VR-4's health and longevity prospects! Apologies for the /Hijack, Richard.

ILLEGAL
24-11-2010, 06:47 PM
elnevio: not a problem mate, thanks.

i must add to that, the factory rear diff housing (not the internals) would be another week point just because it has been desgined wrong, with its mounting points snapping off quite easily. as well as the factory connecting rods in the block, they look similar to a lancer GSR rod but keep in mind there are 6 of them. we have seen afew pop out from abuse by standard turbos running 13psi!!

performance wise the next hold up on these cars is the intake cam, which stops us making much more power over 240KW ATW.

just for infomations sake, my car and engine (original) has done 265,000Kms todate and the last 100,000Kms i have put on myself. from the first week of me owning it it has never ran lower that 15psi and prior to this new turbo install was running 20psi thru the TD05hr... now when i bought it i changed the oil twice in 1 day so i knew all the black stuff had been flushed out.. from then on its been replaced every 5,000Kms with filter. so i do believe servicing is the key to any car keeping its cool :)

bradc
24-11-2010, 06:57 PM
Actually Nev the suspension is 95% the same between the 7G and 8G. Obviously the engine changed which way it sits in the engine bay and both exterior and interior were fully updated, but there are a few common things between them.

ILLEGAL
26-11-2010, 06:51 AM
we found abit of space at the joiner pipe, so we ended up taking the dump for the wastegate off there. still going to run the gate's pipe forward, so the gate will still sit infront of the gearbox. but this is easier to make this and wrap in heat wrap. we will be using 5x10mm steel straps from the main pipe to the wastegate pipe for strength, so the wastegate dont just fall off!! Still going to use the same 50mm item i had in the last setup and will be venting to atmosphere. baaAAAAARRP! but it will have a two bolt flange on the open end so i can block it off for WOF time.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/wastegate2.jpg pipe for wastegate.. top view

http://i672.photobucket.com/albums/vv88/2ILLEGAL/wastegate3.jpg pipe for wastegate.. view from where the gate will sit/ infront of the g/box.


Also while we were talking about braces for the wastegate.. i brought back up the issue of extra bracing on the turbo.. from the valley on the head/block. we both eye-balled it for a few minutes and said..."NAH" ... it should be much better now that there is a brace from the gearbox upto the turbo.. like i said, it was really just the weight of the turbo that bent the mild steel manifold before, because there was no brace on it at all.. the manifolds were holding the turbo on their own. and after a year gave up trying to hold it up, BENT and cracked. but a great observation on your part mate. more ideas floating around the better i say.

VR4WGN
26-11-2010, 06:58 AM
awsum updates but ithink we shud get this moved to pictures i think or performance mods so its easier to track

ILLEGAL
01-12-2010, 07:48 AM
Soooo close now... just a few 3"-2.5" 90degree joiners away from finishing fabrication!!! just 1 off each end of the intercooler.

here is todays updates..

.. first off, yesterday we bumped into a small problem with the fuel rail... it was fouling against the new plenum.. just the nobs on each end and also the fuel regulator.. after going over Nicks build (MSPORT) we noticed he had taped some tails into his rails, so off to the supplies shop i go to get some fittings, and as always.. the bins the fittings were meant to be in were empty!! no problem, over night delivery was good enuf for me. these should have been finished later on today.. but while i was there dropping them off i got some pix of the almost finished product.

this is the airflow meter, i will run it to get a nice base map before i look at fine tunning it with the LC-1.. i figured new turbo.. new power curve.. i better be safe and use the AFM to give me a new base map.. i had to use insulation tape on the AFM so the 4" silicone pipe sealed up nice around it with no leaks!

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0072.jpg AFM with tape around itso the 4" hose will seal 100%

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0074.jpg AFM with 4" hose on it




and in these next few pictures.. is a good look at the wastegate and its dump pipe with a 2 bolt flange. i will block it off for WOF's with a blanking plate i have.. i did have it venting out the bumper on the td05, but it was abit too dodgy for me so just dumping down to the ground this time around..

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0048.jpg View of wasyegate from under

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0049.jpg View of wastegate from side

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0059.jpg View of wastegate from top




this is the brace that will be holding all the extra weight up of the turbo, wastegate and exhaust.. its around 5-8mm thick? and is bolted to the gearbox, we also used bolts on the manifold end so its easy to work with when taking off..

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0050.jpg View of brace from gearbox to manifold




the next picture is of the exhaust with the 2 bungs in it. the first sensor (which is installed) is the factory narrow-band o2 sensor. the bung behind it which has a blanking bolt in it is for my LC-1 wideband sensor which was kindly sold to me by MSPORT member "EVILVR4" for dirt cheep with guage, i will wait untill i need to use it before i plug it in...

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0051.jpg View of o2 sensor bungs



and to finish this update off, a few random pictures of the over all view of the car from around 10am this morning.

the first picture shows the only parts that are missing and still to be completed.. on both side of the intercooler will be a single silicone join goin 90degree off the intercooler steeping from a 3" down to a 2.5". the passinger side looks finished but it will be replaced with aluminium pipe and the 90degree hose. this is so there will only be 4 silicone hose joins on the whole thing.. turbo-pipe.. pipe-intercooler.. intercooler-pipe.. pipe-throttle.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0063.jpg front view of 75% finished product

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0071.jpg drivers side view of engine

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0060.jpg close up of turbo drivers side

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/PICT0059.jpg close up of turbo passenger side

sweet tomorrow i can undo it all and start on the heat wraping, after thats done i can start re-running all the vac' hose, extend the TPS wires and give it a lube flush.. then the first re-start in over 3 months.. well thats the plan, we all know how easy it is to say!

BEG4ME
07-12-2010, 06:36 AM
One thing i can see that i'll be jealous of, will be the ease in which you can change your spark plugs. Haha. Looking pretty good there man. Will look heaps better when you get the 8-G kit on.

ILLEGAL
11-12-2010, 08:47 AM
video online .. http://www.youtube.com/watch?v=UtgNoaWrHs4

okay got it running today for the first time in ages!! the battery was flat but after hooking up the jumper leads it fired to life :-D i started to edge the car forwards when i heard a small POP... followed by the steering wheel going heavy.. seems the P/S hose poped off! so that is now the holdup. will get hydralink to make up a new hose for me on monday. if all gos well i can go for a drive down the street and see if theres any boost in it.

random pix and a video of todays startup

http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/DSC00154.jpg over all shot of the car



http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/DSC00155.jpg left side of engine




http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/DSC00158.jpg good pic of the progress



http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/DSC00156-Copy.jpg another view of the engine bay put together without strut brace.



http://i672.photobucket.com/albums/vv88/2ILLEGAL/6a12%20td06%20upgrade/DSC00152.jpg photo of the engine from drivers corner

BEG4ME
12-12-2010, 08:32 AM
Just out of curiosity, are you cert.ing this?

ILLEGAL
12-12-2010, 08:50 AM
no need for a cert.. makes no more power than factory ofcause :) shhhh! i think after the front end conversion it could be abit harder to get a wof.. but should still pass??


didnt need to mention single turbo on the cert plate my friend has.. single t3/t4 on the same engine.

BEG4ME
13-12-2010, 08:27 AM
Just needa find the right wof inspector. One that doesnt know the difference between the generations. Haha. Looking good man.

ILLEGAL
13-02-2011, 09:05 AM
a video of the new turbo install. its abit long but you get the picture.


http://www.youtube.com/watch?v=4AYQQu3wBhQ ...updated video of finished install.

TAR
13-02-2011, 01:03 PM
good video. The car sound great and goes well looking at the drag run.

Well done.

:happy:

ILLEGAL
14-02-2011, 06:05 AM
thanks, funny thing is the car wasn't running well during that run. when i shifted to 4th the car started missing and splattering and i didnt hold it on the limiter for long enough to get the boost up off the line (2.0 60").. i later diagnosed the missing and splattering as the AFM getting a wrong reading as i had removed the headlight and it has no filter on it. so with 170kph winds being forced up it, it was pumping so much fuel in it wasn't burning. next meeting this Friday, i will keep the head lights in and try get some mesh infront of the AFM, i will get some on board footage this time. and use the mapecu2 to gather some data logs of the runs, its about time i used the damn thing huh.

BEG4ME
14-02-2011, 06:09 AM
WICKED!!! Hope you're bringing this thing to the meet on the weekend. Wouldn't mind seeing it up close. Umm, I think Scarles may be a bit offended at you calling them Scrales at the end of youtube clip. Gotta love the O's on the TVs. Haha.

ILLEGAL
09-04-2011, 10:40 PM
im very happy with the way the engine bay has turned out so far.. i have a few things in the pipe line. im painting the car satin black and getting 60mm taken out of the ride hight. but as payment i have to wear the workshops brand all over the car for a year. not a bad deal, i thought?

a few things that have happened to the car lately..

went to night speed drag wars last night (8/4/11) not a good out come! my clutch slave cylinder thought it would be a good time to give up.. i knew something wasnt right before attending! it was during my approach to my second practice run when the clutch pedal fell straight to the floor... it was feeling abit soft on the way down. i got pushed off the line by the staff there ...but!... i did end up completing 2 whole runs after that! but the gearbox would not have like it at all.. literary BANGING it through the gears with NO clutch (pedal sitting on the floor) so you cant say i wasn't trying. got it home the same way.. start it in gear and slam it through the rest of the gears. got up this morning and removed the slave cylinder, went upto pick-a-part and got a new(second hand) seal for inside the cylinder from a mivec mirage. re-installed this and bleed it and now its feels much more solid than it ever has?? it could have been damaged for some time? who cares.. fixed now :)

ended up coming 1st equal in DYO for the whole season. next season (winter wars) should be good as the car is almost running 90%... i dont think they ever reach 100%?

aboo
09-04-2011, 10:57 PM
Sounds like your getting there. Look forward to see what your times will be next season/yes

ILLEGAL
01-05-2011, 08:34 AM
just a small update...


purchased a pair of used legnum headlights this weekend for the 7.5G front conversion.. im now on the hunt for some FL guards and a bonnet. for cheap or free, damaged a little is okay. just saying.


also.. http://www.youtube.com/watch?v=5apGC_GRPcc i have been rolling the bosses merc for the weekend.. the front rims (not only the tyres) are tucked under the guards.. and it does turn :) S320 slammed on 20" wheels. not a bad look? i prefer BMW over girly mercs... but this one has grown on me.


http://www.youtube.com/watch?v=_O0kpFhWq9k&feature=related this is the advert i created from the footage i had taken... i would be keen to offer a video of anyones car. i can include a full inscription of your mod list and a small interview of yourself. if interested please PM me.

Gly
01-05-2011, 09:45 AM
front guards are all the same, pfl or fl,
just the added option of flairs which can be semi hard to track down at a reasonable price

ILLEGAL
17-05-2011, 01:29 PM
Time for a new look?


Crystal (my Fiance) started work on the car today. We are painting it Black. here is what she done today for me.

... i did help... i showed her where the tool boxs are.

FRONT DOOR http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00327.jpg

BUMPER http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00329-1.jpg

REAR http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00344.jpg

ROOF http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00334.jpg

cRYSTAL WORKING http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00325.jpg

MarkSanne
17-05-2011, 01:59 PM
Good work ;)! Nice & shiny black or...? (one of the dutch guys 'uray25' owns a 7G VR4 in a beautifull black 'ish' and I love the look of that car, even though I'm not a huge fan of the 'default' 7G looks).

ILLEGAL
17-05-2011, 08:41 PM
we going with a semi gloss black.. i believe its called satin black? not flat or gloss but in between. im not sure what to do with my wheels...i will just leave them for now.

Gly
17-05-2011, 11:07 PM
how come you not doing the 8g front end first? seams a bit sad to waste paint and time on a front end thats not staying on?

Oggie
18-05-2011, 07:40 AM
we going with a semi gloss black.. i believe its called satin black? not flat or gloss but in between. im not sure what to do with my wheels...i will just leave them for now.

yeah satin black sounds about right.. semi matte/gloss. I my self have come to love matte black if done right with a matte clear coat for soem protection.

BTW looking good on the car.

ILLEGAL
19-05-2011, 07:51 AM
the reason we are painting it before the front gos on is because theres a event on the 29th of this month at hampton downs and the boss (my actuall boss) wants it painted and sign writen for that... im still on the hunt for a cheap/free bonnet and grill.. and with the custom work involved we didnt think we would pull the conversion off in time? the paint is cheap and the labour free so dont see any harm with this now... might have to pull out of the winter wars this year to concentrate on the conversion.. should look great next summer if all gos to plan. we have made our minds up with a charcoal colour for the wheels basically what they are now but fresh.

Gly
19-05-2011, 08:49 AM
i have a prefacelift grill you can have free,
one of the feet, the clips mount too is broken off, and another ones coming off? (could be glued?)
other than that its fine

prefer if you can pick up thou (im in manurewa)

ILLEGAL
22-05-2011, 09:12 AM
almost time to paint the car... the body was in very bad shape.. anyone who has seen this car knows its no a show car.. but its alot better now after almost a week of bogging, new tech and sanding. went to apply the primer today only to find its the wrong stuff! i got bored after that and hit the calipers with fluro green road marking paint... should look not to bad once the car go's black... also done inside the fuel flap.. just for the fact i could :fu: let me know if you think its balls.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00572.jpg full car over view

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00561.jpg front of car

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00567.jpg green brakes

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00562.jpg green brakes close up

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00570.jpg green brakes extra close up

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00565.jpg fuel filler flap.

ILLEGAL
23-05-2011, 11:23 AM
just a few more pics of the paint job... just done the primer FILLER tonight... will block it all down tomorrow after work.. then at night hopefully get some colour on it. even as it is, its looking pretty smart! also happy theres no holes in the boot lid and where the aerial use to be aswell as where the front badge use to be.

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00610.jpg front, no holes from badge

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00609.jpg front, close up

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00602.jpg boot lid, no holes

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00603.jpg boot lid other direction

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00601.jpg no hole from aerial removal

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00598.jpg front bumper and window trims

http://i672.photobucket.com/albums/vv88/2ILLEGAL/DSC00596.jpg front bumper, another angle

BEG4ME
26-05-2011, 07:38 AM
Don't think i've ever seen weather strips been painted before. How is the sign writing to be done, because if it's stickers or something covering the paint, you'll most likely find that you'll get mean fade marks once removed aye.

ILLEGAL
26-05-2011, 01:07 PM
easy bro.. will just have to D/A it with some 400 and splash a top up all over it. at least by then we will be in the new shop.. with a booth, heated and silicone free! damn groomers!

ILLEGAL
29-05-2011, 11:27 AM
car is broken!!! will keep you informed as to what it is. also got footage from hampton downs that i will post up

ILLEGAL
23-07-2011, 12:25 PM
re posted below.

Nutter_John
23-07-2011, 12:35 PM
Richard rather than linking to Photobucket can you please upload the onto the site , that way if your photo account dies people can still see the images

ILLEGAL
23-07-2011, 01:05 PM
so finally have a new engine here for [ILLEGAL] stock standard 6A12TT, from Kempys, 140,000Kms on the clock, cambelt done, engine is dry and clean. took photos of it as it arrived at work...

4698246983


got stuck into striping down the new engine today. removed the... factory plenum and injectors, front turbo manifold, rear turbo oil feed and return. after that i placed the custom plenum on to take these photos of the engine...

469844698546986


will be keeping this one factory on the insides just like the last one. this time i want a better oil sump (baffled) and a cooler. will stay with the TD06 25G running 20+psi and the rest of the previous setup. i hope to get it ona dyno this time to get it running without being sooo rich in the A/F ratio mixture.. swapping spark plugs every event wasnt cheap.. neither was the oil change just as often as i want to avoid a bore wash situation. i have tinted the windows on the car with 35% black. and am currently looking for someone to lock my vcu so we can run in RWD or solid 50/50 4WD when need be.. im wanting to attend more events next summer and alot of the revolve around skids and drift/ghymkahana, ofcause im still looking for the magic 11 second pass down the strip , perhaps the locked center will help it off the line... will also try 2nd gear limiter launch so i can see... #1 if it can launch in 2nd gear 4WD... and #2 see if it helps bring my 60' down closer to 1.8 - 1.7 ... previously running 12.8 on a 2.0 60'.

so i have alot of plans on the go for this car.. almost have all the parts to start the 8G/Legnum front conversion just need bonnet and radiator support (pic-a-part)... i need to get the rocker covers polished along with the plenum. paint the gear box silver and paint the heads and block silver aswell. i need to find someone to lock the vcu. i need to fabricate a new rear diff cover plate from mild steel. i also want to upgrade to F/L brakes all round aswell as the 5 stud hubs. im currently getting soild engine mounts made up. will be finishing the in-car entertainment and re installing the water/ methonol injection.

Nutter_John
23-07-2011, 01:27 PM
Thanks Richard , so much eaiser to view the flow of the thread now

ILLEGAL
30-07-2011, 10:04 AM
got the rocker covers and fuel rails polished today... plenum gets its turn next weekend :) all came out very very clean even the fuel rails.... i removed the factory "V6 DOHC 24v" embossed writing from the front bank with the D/A sander, prior to dropping them next door to us at work this morning...
4716347164



once i got them back (2hours later) i noticed i would/should paint inside the spark plug area just to tidy it up.. i cant wait for next weekend when the plenum get done aswell...
471664716747168


here they are with painted spark plug area....
4716947170

QUESTION: do i paint the heads black silver or a colour??? or leave them cast?? and the block ?? black? silver? or cast?

im thinkin black heads with silver block and gearbox.. opinions please?

Oggie
30-07-2011, 11:48 AM
how much did the polishing cost?

ILLEGAL
30-07-2011, 12:46 PM
next to nothing. any thoughts in regards to what i should do with the heads and block, finish/colour wise?

horndog
30-07-2011, 12:54 PM
What colour is the outside + brakes/badges etc gonna be?

do you want a theme for the entire car?

ILLEGAL
30-07-2011, 01:18 PM
it looks like this now..... but will be getting the 0800BESTDEAL LOGO down the sides ... NO badges.


http://www.youtube.com/watch?v=IuEM2JjvvII&feature=channel_video_title



47173471744717547176

ILLEGAL
30-07-2011, 01:24 PM
and this is the engine bay...

http://www.youtube.com/watch?v=4AYQQu3wBhQ&feature=relmfu

horndog
31-07-2011, 09:04 PM
QUESTION: do i paint the heads black silver or a colour??? or leave them cast?? and the block ?? black? silver? or cast?

im thinkin black heads with silver block and gearbox.. opinions please?

Black heads with silver is a good choice, I've always like the look of red blocks though - dont ask me why

ILLEGAL
02-08-2011, 11:20 AM
took some teaser photos tonight :3d: im just waiting on the welded vcu and mild steel rear diff housing and solid engine mounts before i put the new engine in. this photos are of the blown engine with the polished covers...

472234722447225

scott.mohekey
02-08-2011, 11:28 AM
Looking good.

ILLEGAL
24-09-2011, 09:36 PM
i took afew more parts to the polisher yesterday.. just the power steering bottle and the 2 brackets for the ignighter and the coil packs.. i never knew but the coil pack bracket actually has numbers marked on it.. guess i had that much paint on it i never seen it. its all comming together nice now.. given up trying to move the fuse block... too much time and effort for now.. but will get stuck into it next time a motor gos pop. i keep telling the bro who does the polishing thats about it... he replys, there will be more you want done.. and what do you know as soon as i get the parts back.... i find i now want the radiator brackets done and abs setup as well as the brake booster and clutch master cylinder. lol.. then that MIGHT be all ??? :)

also i ended up just respraying the block and gearbox black.. thought to myself it would be easier for me too keep it black then to keep it shiny silver :P and got a new FFM Helmet for my birthday from the bro's. its sooooo comfortable..


485114851648515485194851748514485124851848513

Gly
25-09-2011, 12:04 AM
looks good, bit more bling in the rebuild :D

BEG4ME
26-09-2011, 01:07 AM
Is that just heater hose for your rocker cover breather? If so, you'll probably find that it'll just perish with oil contamination.

ILLEGAL
26-09-2011, 10:10 AM
not sure what hose it is Jordan.. but i told the sales person its use is oil and heat resistant.. im sure we can just change it every so often.. besides that was just the setup for the time being... what it should be is all 3 nipples from both covers will each have its own hose letting the engine breath much better... 3x12mm breathing hoses as oppose to the factory 1x12mm hose. we managed to get the engine sitting on its mounts in the bay tonight. will go shopping for new belts tomoro (alternator and power steering) then will mount that massive turbo back on the side of it.. i plan to have the car ready for October 15th.. HORI DORI drift days.. will be repping the triple diamond flag loud and proud! assuming theres still a spot available at the time. so far so good!

ILLEGAL
04-10-2011, 12:09 PM
so after sooo long we actually have the new engine in the engine bay.

also the top engine mount was dropped off too the workshop today.. matches the front engine mount now. i have also removed the bracket for the A/C pump alltogether and got a new shorter belt... also gave the alternator a birthday and a new belt. not to mention a brand new set of NGK leads and plugs regapped to 0.7...

at the moment im just glad to see it sitting in the engine bay... bugger all to go now.. throw the turbo on, plug everything in, radiator, plenum, PS2 :oops: um yeh....) , change the oil filter and fill all the fluids up.. could be going by this weekend if im lucky




4879448792487934879548791

Humpty's Revenge
04-10-2011, 12:44 PM
That is looking great Richard. May I ask what belt you used for the power steering please dude? What from & make/number please? Cheers buddy.

Nutter_John
04-10-2011, 01:20 PM
steve measure the lenght you need and the number of vains , then just use a belt with that info from any car

so if it is 627mm long and 6 vains the normal part code would be - 627pk6 etc - most decent motor factors will be able to find one very close

ILLEGAL
04-10-2011, 01:24 PM
not sure what the part number is... all i done was got a piece of speaker wire... wrapped it around the pulleys... cut it to fit so i had the size the belt should be.. and bought the belt the closet size down.

Humpty's Revenge
04-10-2011, 01:33 PM
steve measure the lenght you need and the number of vains , then just use a belt with that info from any car

so if it is 627mm long and 6 vains the normal part code would be - 627pk6 etc - most decent motor factors will be able to find one very close


not sure what the part number is... all i done was got a piece of speaker wire... wrapped it around the pulleys... cut it to fit so i had the size the belt should be.. and bought the belt the closet size down.

Thanks guys, I am doing away with the A/C on my conversion & that could of posed a problem with the belt. I'm not starting mine until I have everything but I is getting there.

--hoff
10-10-2011, 09:10 AM
from your setup, I am worry about your coil distributor getting melted from the heat of the turbine. I doubt eventhough with good turbo cover it will still able to melt it.

If you only use it for drag racing I don't think it's going to be a problem...But if your are using for daily driving, i think it's going to be a problem.....


took some teaser photos tonight :3d: im just waiting on the welded vcu and mild steel rear diff housing and solid engine mounts before i put the new engine in. this photos are of the blown engine with the polished covers...

472234722447225

ILLEGAL
10-10-2011, 11:13 AM
hmmm yeh about that..... my fuel lines are also right there.. so.. going to look into a beanie for the turbo and might place a heat shield on the coils.. i drove it with the old setup for approx 30,000kms daily but the turbo was low mounted infront of the gearbox, but the joiner pipe/turbo manifold ran right next to it and i only used heat shield. i still have the coils from that old engine and they seem fine. so i hope the beanie aswell as the shield will do it for me....

in other NEWS!!!

after the better part of winter we finally managed to breath some life into me old faithfull... well atleast long enough to get it to operating temps and abit of a drive. i only drove it 50mtrs down the road and back as its not road legal yet. drove off fine but it sounds strange from what i remember the previous engine being.... it could have been the engine mounts or the engine but we will have to wait for next week as i have managed to blow the MAPECU2 while jump starting the car after the test drive... sent the ECU off today, and can only hope its here before the weekend. also it felt real jelly/floaty with out the strut brace in there i hope it feels better with it in. next time its running i will make sure a video camera is present. was soo cool to just pop a skid sooooo easy... then when boost winds in its just carzy!!! going to be alot of fun/trouble in this car now.



489234892448925489264892748928

ILLEGAL
24-10-2011, 09:14 AM
so at long last i go a good camera man on the job.. went to his car park and done this... http://www.youtube.com/watch?v=XY6qUL4Cwro ...The cars water temp went above half way just after the stand still part so i stopped.. it didnt get near the "red" but it looked like it was on its way?? so i have a question..

Q: how hot is acceptable when doing skids??

i would have thought my 53mm radiator would have coped or would it be something else?

Gly
24-10-2011, 09:30 AM
your radiator can be as big as you want, but if theres not sufficient airflow though it, it will still get hot,
its just a big heat sink.

and those slim line fans (dunno if thats what you have??) barely cut it sitting in traffic (this is what ive found in a twin push though fan setup) so doubt they will be doing much sitting still, while reving the **** outa it

normal op temp, running fully warm should be 85degrees, this is the engines ideal running temp,
95-99degrees is just below the red on the cars dash (the dash gauge is crap imo)

as for acceptable temp, i would be worried about anything thing higher than 95degrees for more than a few minutes.

ILLEGAL
03-12-2011, 09:01 PM
sooo guess what i have managed to do at the drag strip this last friday??? i, at long last have managed to blow the casing on the rear diff.. what happned is i had my first RWD run down the strip.. every thing done as i normally would but i didnt flat shif... i managed to complete my first run although the clutch was slipping all the way down and had to feather the throttle in 3rd and 4th. managed a 14.6 @ 170kmh from a 2.2 60' so although a good time in my view.. it wasnt anywhere near the 12.8 it ran day in day out in 4WD...

Anyway ... on the 2nd run down the strip.. i thought F*** it, so i thew caution to the wind and loaded up 1st off the line @7200rpm.. poped out the clutch and it actually grabed and got the tyres spinning... went to select 2nd gear.. flat shifted the change and.... BANG!!!!! wow WTF!.. lol i KNEW what it was straight away.. for the amount of info here on MSport i knew the 2 lil tiny ears on the rear diff had snapped off before anyone had even seen it... got me in abit of trouble with the saftey crew.. because i told them it was my diff without seeing it they thought i had come out to race with a already broken diff... i had to explain that i only knew/thought it was the diff because these model cars are notorious for it... after dragging me off the track i managed to get out of the car and have a look... sure enough it was as suspected... diff mounts were where they were meant to be but the diff was sitting down on the exhaust. ALSO. the drive shaft had snapped off at the dif aswell, i guess because when the diff fell of it put the universal at a weired angle and snaped it?? got it towed back to the workshop "thanks AA"... and pulled it off..... found the dif inside is 100% fine, confirmed the twin lines i leave up and down the street are because its viscious LSD! yey!.. so plan from here is.. i havnt heard from BATMAN about his much appiciated efforts to get a plated rear diff cover up to me (understadable mate) soo im taking the jig-saw-puzzle that is my broken cover to the engineers tomorrow to have one made for me. heres the picks i have...

--hoff
29-12-2011, 02:30 PM
wew that looks really bad....I guess this car wasn't meant to be a RWD....

ILLEGAL
29-12-2011, 10:14 PM
:P it would look even worse had the gears given way.. it was just the cover and if you look close you will realize its a design fault with the 7G galant and gt sports of this era.. insteed of having the mounting bolts closer to the center of the cover where they could add more meat to it they have them way out to the corners.. and made from cast approx 2-3mm thick they snap off easly, even with the torque shared by the front drive.. i just got lucky to have mine last 3 full seasons of drag racing .. not many others lasted as long...

i have a 8mm? steel plated version of the cover to replace the crap cast factory item so should be able to load it up alot more.. also once i get it back in im gona see if i can get the top 4 bolts of the cover to bolt upto the sub frame aswell in theory quad-dulpling its load rating.. it will be fun to see what breaks next aye??? my bets on the half shafts.

at the moment its fwd... = more hp.. gota look at the bright side of the story i guess :P

darkraid
02-01-2012, 01:03 PM
Wow. Great read. You have come a long way with the car since you bought it. Great to see all the things you have done to it.

ILLEGAL
30-01-2012, 06:16 AM
so whats been happening??

i have a few photos i want to share just to show where abouts im upto on my ca [ILLEGAL].. first of all im very happy i now have my personal plates on the car and its about time.. all my youtube videos have people asking "whats illegal about this" lol.. it s the name i gave the car derrr!

any how.. re: cannonball 2012.. you saw the theme and guess what.. it was award winning :) yup we got best themed car and team.. for this award i received a prize pack consisting of 2x 10" kicker pre boxed woofers, a bnt voucher and a mambo bag.. and a free entry to any Auckland motors sport event and a trophy. not only that but i myself won the "mr personality" prize for being the life of the party on the day :) for this i won a bag full of party pills from enjoi and meguirs pack and a trophy. so we walked away with 2 trophys and a boot full of gear.. heres a 15 minute video of our day ...

http://www.youtube.com/watch?v=xuAk2ouZyi4 <<<<VIDEO LINK****





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abit of a laugh i know.. what can i say? we had a great time.

anyway, im still trying to get ahold of a friend in regards to this steel plate diff cover with no luck so far.. i managed to stop progress on the cover that a local engineer was going to make up for me.. starting to think ill just bite the bullet and get it done?? but i have a new cover of the factory kind so ill just be gentle with it untill a custome one shows up.. in the mean time ive had a bit of bad luck with the car in FWD?? it seems ive either blown the centre diff of the gearbox itself.. i did for a moment think it was going to be the weld on the vcu but that still looks solid... but the oil that came out... well, i didnt know they made gun metal grey oil.

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so i can only assume something else has now got no teeth? easy just get a new gear box aye?? after searching for a few days and coming close to giving up looking for a box and thinking of just getting a whole new car (sport gt) i found a replacement gearbox. i didnt tell him i was having troble finding one and picked it up for only $300 from parts west. story behind this box is its from a car that crashed and had only done 90,000ish kms 5 years ago.. been sitting on their shelfs since then because the previous few e84a boxs they sold were of the other ratio.. im the first to ask for this ratio.. in 5 years?? um okay? ill buy into it :) it was very dry but still had all its fluid inside it.. it wasnt metalic but it was abit burnt so i guess it could well be the original oil inside?


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got everything off the car last night thanks to markys "how too" in the tech archive section @ msport.co.nz.. other wise i was looking at just pulling the whole lot out.. motor and all. but this worked well.. i also pulled the clutch off so i could install my new (second hand) plate inside, and OMG!! guess what i found.. results of "trying" to start a skid in 3rd gear in the dry....

pressure plate
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clutch plate
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and flywheel
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it is hard to make out in these photo's but both the pressure and fly wheel had abit of burn on them.. my quick fix was to attack them with some 255p sand paper on the DA sander.. got them all flush again and very shiny.. so i could install this bad boy right here.. its a clutch master fx300 plate and is made to have more bite over the exedy i had and hold more torque.. believe me ill be testing that :)

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here it is all back together.. the clutch.. now i have to wait for tomorrow to buy a new release bearing as the one i have seems to move sweet but has a small noise to it so id say its poked!.. the fork is fine, as well as the slave cylinder.. also gona get a new master cylinder and have a braided line made to go from the master cylinder to the slave and get rid of the massive long path it takes at the moment.

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also.. a small step side ways.. i have purchased a new carpet set for inside the boot... a mix between galant parts (plastic side pocket, and top carpet) and emerald parts (bottom carpet with built-in lift up tool box) i thought seeing as the new woofer would look out of place with the whole "race spec" boot id tidy it up abit.. this set me back all of $30 including all the side trims to match.. im on the hunt for a new new looking carpet for inside. my seats are fine so are my door trims :)

heres the galant carpet looks as it should.. i just want to trim it by the battery box to tidy it abit more..
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and here is the carpet from the emerald it has the plastic "tool box" part thingy that i thought was cool so i bought it :)
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and to top off my turbo install, i finally got around to purchasing a turbo beanie for the lil old td06.. im thinking of making a small stencil out of sticker [ILLEGAL] and spraying it with exhaust paint then removing the stencil to leave the image [ILLEGAL] on it?? i dont know, thinking out loud again..
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and you might laugh at this but i have a 17" G-ZERO laying around home here so i have decided to use this as my spare tyre for now :) havnt had a spare in the last 4 years. if you wana help me out with ideas on if i should paint it or keep it chrome.. your welcome to comment :beerbang:

ILLEGAL
26-02-2012, 09:29 AM
okay, update time..

WHAT A MISSION!!! is one way to put it.. now as you know i bought a used gearbox to replace my broke original one.. long story short.. the replacement was broken aswell!!! i got it all back together and fluids topped up ready to bleed/fill the radiator, i had the car in neutral and tried to start it.. the car jumped forward!! yup in neutral it tried to drive off on me???? started fine with the clutch in but let it out and it just wanted to drive off?? anyway pulled that out and opened them both up.. i had no idea what i was looking at but what i could gather was the gears 1 and 2 were sandwich together sort of on the new box, and i found inside my front diff in my old box had busted its spider gears so i swapped the diff units out.. so im now running my old gearbox with the new front diff.. and works fine.. ive also converted it back to RWD with a factory diff cover and replacement drive shaft also factory. but i have made a few changes to the mounting on the sub frame for the diff.. in these next few photos you will see i have removed the old rubber centered mounting bushes and welded in place some mild steel items i had made up to fit...

heres the remains of the old rubber setup.. i removed this..
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here is the bushes i had made before welding started..
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here they are welded up and installed on the subframe at the rear..
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heres a look at the LSD diff itself, it now sits very firm and it is very noisy from inside the car.. sounds like its broken?? but i guess thats normal for this sort of thing?
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now seeing as i had to pull the whole gearbox off again to fix the front diff.. which means i must pull the turbo and manifolds off. i ended up buying afew more things while i was at it.. i have added another layer of heatwrap onto the exhaust and turbo manifolds.. this time i have used the black heatwrap. i have not got any good photos of this yet.. also.. i have given the clutch setup a overhaul.. pretty much all new.. new master and slave and braided hose to join the 2..
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i re-done the hose line for 2 reasons/excusses.. first was because it looks cool having a braided line there :sunny: and second is the fact that the original hose pretty much wraps right around the whole engine bay before going to the back of the gearbox seemed silly to me so i basically removed 2mtrs of hose out of this thing.. after removing the original master cylinder it was obvious that had i not done this now.. i would be doing it shortly.. it was pretty much game over for the seals in that thing..

so.. now all back together and running RWD its time to enjoy it for what it is.. 2weeks and already needs new rears on it.. still lots to do but heaps of time to do it.. got a 8G front and 5stud conversion (still to be picked up from Carsten) but still looking out for some FL front hub carriers anyone.. have my new sound system up and running.. enjoying that heaps.. removed the 3 4awg wires i had running front to back running the battery in the boot and now have a single 0awg wire in their place.. have a fused distribution block up front with a connection to the main fuse block and to the starter motor. i still got to re-install the playstation but dont really need that.. i want a second battery to run all the accessories off it. not really a drag car anymore so more a street fun mobile at the moment.. untill i can get the stronger rear diff cover or a better way to brace the rear diff better.. i enjoy driving this thing more now it has good sound. and still keen to learn drifting in this car.. but it also needs a good tune up.. i still need to rewire and plumb the water/meth injection kit before it gos to a dyno so they can tune with that aswell.. but all in all.. its alive once more and being week 2 its been alive for its longest time in a long time. i only seem to get 2 weeks out of this thing when i get it going. so that concludes this update.. for now.. chur.