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mostly contour stuff

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Done

well I found out that the bolts for the waste gate came loose again. But I am not sure that is where the leak is from. All I know is that if I look straight up at all the pipe from under the car the exhaust is coming straight down. So I think I will be pulling the turbo and wastegate again tomorrow to re-seal everything. Car sounds pretty good, the exhaust was to quiet before the leak.   anyway ....                     Also so far eveything is fine with the waste gate. I check the bolts again yesterday before driving the car and they where still tight. So hopefully that is all set.   Since recently my optima redtop only seems to read 11.5 volts at the volt guage I ordered a new one. I don't know if killing it twice has anything to do with any of the low voltage that I see at time. But anyway I am going to pull the alternator and clean the contacts inside to see if that helps also.   Also the car seemed slower then it has been yesterday, but then again it was hotter also. Anyway its time to install the mbc also.

BrApple

BrApple

 

98% complete

well tonight I was finally able to install the intake tube and air filter. I had to trim alittle bit more from the fender area to fit the tube but all worked out. After that I was going to mount up the power steering cooler but I found that the bolts I bought which I thought where the same where not. So I just left it how I had it. After that I drove around the storage area. There was no irratic idle as I had before. Some of of the drive way area had just been re-tared. I easily left 10 to 15 foot strips in a few places without trying. After that I went for a road test. The car performed really well. I just did the loop around the block a few times. The car pulled nicely and was well manored. I put the bumper on for a test fit and found the filter contacts the fog lamp. So I think i will cut the intake tube about an inch shorter to make it clear. It also looks like it maybe to far out to install the bumper so I might have to modify the fender openning some more to get the filter to tuck in more. Oh well just more to figure out tomorrow. But at least the kit is installed completely and works      

BrApple

BrApple

 

back on track

well it took from 5 to about 8~8:30 but the wastegate exhaust leak has been corrected. To get the wastegate out I had to dissconnect the exhaust and remove the downpipe with the wastegate attached. Well to my frustration it wouldn't go back together that way. So back out it came and I also had to unbolt the turbo to get everything to line up. Again the allen wrenches with the ball end ftw, I was able to get to all four wastegate bolts with one. Now after hitting boost I can really hear the blow off valve. Down side was I still wasn't able to get the intake and airfilter installed. I did however get a new coupler to replace the one I cut to short. So hopefully tomorrow I will be able to get that installed. I also have to remount the power steering cooler to the bottom of the intercooler. After that I will be able to get the bumper re-installed and road test everything.

BrApple

BrApple

 

one problem

well I kinda broke it already ....     that exhaust leak is at the wastegate. I thought I had it tightened down enough but I was wrong. That first time I really got on it the gasket on the up-pipe side blew out. I tightened then down more today but what was done was done. I was over excited to drive it. So my hope is that I can just pull the two bolts and slide the old gasket out and slide a new one in. otherwise I have to pull everything back out. At least I can get to three of the four bolts fairly easily. So I think I can take the two bolts on the blown side out and then the third that I can get to and rotate the wastegate out of the way alittle.   have to see. the only down side is it is leaking metered air so its going alittle lean at idle. however under boost the A/F is good. I think that I will also take the chance to re-run the oil drain. right now it runs behind the header to the tap in the block. well its very close to the header, however it does have a 2k degree thermal sleeve over it to protect it from the header. I am thinking about putting the nipple right into the block and then running the oil drain in front of the header to the block. This way its away from the heat.

BrApple

BrApple

 

day two

so yet again another long day getting the turbo installed and up and running.       The morning started off with getting all of the hot side piping and turbo installed. By early afternoon that was completed. I then went about getting all of the charge pipes installed. Alot of the couplers needed to be cut down to make everything line up correctly. All in all that wasn't that bad to do. I did however cut the one to the inlet of the turbo to short. This brings the maf enterence up to high so I wasn't able to install the intake pipe and air filter. On start up the car idles very nicely. After pulling it tends to want to die but alittle gas helps that. With the 3 psi spring the boost comes right up to 3psi and sits there, meaning that everything is working as it should. the bov isn't that loud but in the storage unit I can only go fast. I think it isn't that loud because of the low boost. The first time I was able to shift to second on the power an exhaust leak developed. With Rogers help we quickly determined its the first exhaust joint after the down pipe. So tomorrow I will have to go through all of the exhaust joints and make sure everything is tight. I will also be ordering a new coupler tomorrow so that I can install the intake correctly.       The boost comes on slightly before the secondaries open I believe. The power is seemless. Rolling into the pedal just makes power and the turbo spins up really fast. The exhaust leak make it sound so bad ass, but that will get fixed.       Pic from around noon time where I had all the hot side piping installed and tightened down.         after running the car the first time and hitting boost      

BrApple

BrApple

 

day 1 continued

the correct tools ftw   I picked up a allen wrench socket set and some stubby wrenches and the plugs for the oil feed and drain came right off. I was able to reinstall just about all of the hot piping and the turbo. The turbo will need to come back out so once it is clocked correctly the flanges are tightened down. Once that is completed the oil drain will be put together and installed to the turbo so that can go back in and I can start tightening all of the hot pipes. After that are the intake pipes and vacuum lines. Should be able to get it done tomorrow.   here we are ....   out with the old/original and semi old   Up-pipe and exhaust piping     Turbo in the up-pipe with the oil feed             The waste gate is a pita to install       WPI ...  

BrApple

BrApple

 

install day 1

I feel like I got my ass kicked today ...   I started off with a new tune from Joey. Everything was running right so on to the turbo install.   I was loaned a hole saw from some other guy at my storage unit, he was working on his car and snapped the allen wrench off in his coil over adjustment. Luckly the magnet I had was small enough to get the peice out.   So I started in on cutting the whole for the intake pipe. It was pretty slow going and the batteries died for my drill pretty fast. So I run over to Home Depot and pick up a corded drill. I get back to it and the hole saw isn't working to well ... go figure it wasn't for metal. So I run over to Sears and got the one I needed for metal and was done within a few minutes. After all of that I got all of the hot side piping installed and was playing around with installing the turbo. Well it was when I tried installing that intake pipe I drilled the hole for that I realized that it had to go in fist before the down pipe. So back out everything came. I then went about cutting the slits and bending the metal back to get the pipe to sit furthur into the frame. I also got the whole slightly off center so I am working on straightening that out also. I then went to install the oil line and hit two snags there. First I cant easily get the plug out of the head and I didn't have a stubby wrench to get the cap off the oil drain. So off to sears again to get what I needed and here I am now, taking a break.   I might go back and do more tonight but I have to see. Thinking about taking it easy as I have been working at this since 9 am this morning.   more later

BrApple

BrApple

 

getting closer

getting closer     I was able to upgrade the fuel system today and tune the car. Everything was straight forward. The injectors and spark plugs where easy to swap. I was able to get it all done since I figured out an intake last night so that I can drive the car. I took one of the intake pipes that actually comes after the MAF and used that to install the 80mm maf and I picked up a cheap APC air filter to use for a few days. The tune was very easy to upload to the PCM and the car did fire right up. For the forst few minutes it didn't want to idle, ie the idle was very low but keeping it reved up for a little took care of that and after alittle time it came right down to the correct idle. I ended up about 5 minutes short of a down pour to be able to actually drive the car and see how it is. The tune I used is my turbo tune. But since my understanding is its set up to add fuel based on the amount of metered air it will run fine either as N/A or boosted.  

BrApple

BrApple

 

about ready to go ...

well now that Spring Zing is done and over I can get back to my turbo project. First up will be the fuel injectors and spark plugs. I have the 42# injectors and the NGK TR6 spark plugs to install. I will then either just make sure the car runs without any fuel leaks or I will try to get the 80mm maf installed so that I can tune the car and make sure it runs. I hope to be able to finish this tonight.   I am giving myself a two week deadline to get this project complete. I would like to take the car to the All Ford Nationals in Carlisle, PA and have it complete and running with the turbo.     Slight change in plans now. I really want to dyno the 3L as it is now before installing the turbo. So if I can make that happen before the weekend I will. Problem is Bristol Dyno where I normally go has closed but its in the same building/shop as Victor Research so I am trying to find out if they can dyno the car on the same dyno as I have been going to.     Some side notes about SZ. The weather was great yet again, lucked out there. The SVT with a KKM, glasspack and 2.5 inch piping from the rear y back to magnaflow mufflers put down 172/154 iirc. Not bad numbers for a pretty much stock SVT with 46k. The SVT also almost won the Show and Shine. It tied for second with 13 votes and lost to the 1st place car by one vote.         Tonight I was able to play around with some of the turbo kit piping that I have and my new MAF. I have found a way to install the new 80mm maf so that I can install my injectors and tune. I was able to take one of the intake pipes that happens to be a 90 bend and run that to the stock accordian tube. The stock tube is alittle large but the pipe goes way in and it clamps down well. This allows me to then attach the maf as this is the same tube that comes after the maf in the setup. Only down side at the moment is I do not have an air filter that has a 4" openning. I think that a friend of mine does so this will allow me to drive the car to make sure the tune and fuel system are working correctly. Still looking to see if I can dyno.

BrApple

BrApple

 

todays efforts

todays efforts in HDR ... one coat Z-AIO and one coat of Z5 applied and removed with the PC ...          

BrApple

BrApple

 

little progress

Got the walbro fuel pump installed in the morning then I got called into work. didn't get much more completed tonight ... but the pics explain all ...       No it isn't connected to anything yet ... didn't get to finish the fuel system upgrades because I had to go into work. I need to made the cuts in the body so I can install the intake side with the larger maf ...   KKM 80mm maf adaptor     I also plan to wrap the up pipe and the other exhaust pipe. And yes I am aware of the possible problems with moisture. And just about each time I drive the car it is brought up to temp and driven enough to dry everything out.     I am thinking this is going to be way to low for daily driving....    

BrApple

BrApple

 

about ready for the turbo

wrapped up the LC-1 install today but taping up the harness and putting the passanger footwell area back together. I then got the data logging software and the xcal2 going to data log the wideband. I was able to calibrate livelink to correctly display the a/f ratio. It matched up just about perfectly with the LC-1 software that I was using to display the A/F ratio.   I learned a few things data logging tonight. at idle a ported 3L will run about 15:1. when shifting it will hit 20:1 or greater. Under load at wot I am reading 11:1. So this confirms what Joey said about my car, its running 15% lean because of the added displacement the PCM doesn't know about. I am glad to see that it is getting plenty of fuel under load. Also at first my A/F guage was not reading anything in the rich zone on the guage. I reprogrammed the output from reading the max of 8:1 after learning the car goes to 11:1 to 10:1. This made the guage display the a/f ratio better.   Also as expected everything I ordered came in today. I now have the proper maf adaptor for the 80mm maf. I placed an order for the two couplers that I need to use this maf and adaptor. I now have header wrap for all of the hot pipes in the kit.   So I don't think that I will have much time to get much done tomorrow but Saturday I should be able to upgrade the fuel system and tune the car. If that all goes well I can start the turbo install. So if and when the fiel upgrades get done and the car runs well I will either get the rear brakes upgraded or start on the turbo ....

BrApple

BrApple

 

the last two days

Well the last two days have gone really well. I have finished up my front brake upgrade. I drove the car last night and everything is well. Now its time to get back under the car and double check that all the bolts, etc are tight. I also finished with my LC-1 install last night. The other night I was able to get everything wired up and running. The problem I ran into after reinstalling the y-pipe and test pipe was I couldn't get the sensor to screw into the bung. Two things appear to have happened. First the bung wasn't centered on the hole in the pipe. This caused the O2 sensor to not go in straight. Second the threads where just rusty and it was dificult to get it started. After filing the hole in the pipe open more I was finally able to thread the sensor in correctly. After this I went about remounting the intercooler and the ps cooler to the cooler. Overall the car ran nice last night. Now with the wideband the A/F guages doesn't just bounce back and forth any more. So that part of it is pretty cool. The LC-1 has programmable outputs. So the 0 to 5 volt output of the wideband sensor signal is scaled and output to the A/F guage.   So tonight the last of my parts will come in. So after getting the couplers I need for the larger maf and maf adaptor its onto the fuel system upgrades.

BrApple

BrApple

 

the nickel and diming ...

is starting to get to me. oh well its a big project   I ordered a 80mm maf adaptor from KKM of ebay today. It goes out in 1 to 2 days and I got 2nd day air so I should have that by the end of the week. Once I get that I will need two new couplers so I can use teh larger maf and maf adaptor. So after that i should be ready for the fuel system upgrades this weekend.   I also ordered a pre-made oil line for the turbo and a new 90 steel fitting. My dad is goign to make a brass restrictor for it.   I also placed an order with summit racing for some header wrap, straps and high temp cable sheiths to use also.   I end up also getting some more dzus fasteners for my mirko for the SVT. Now I have to decide if I actually install it or not. Will test fit it tomorrow.

BrApple

BrApple

 

another weekend down

Well things are back on track with my projects. Going to also go get the SVT tomorrow night   In progress pic of the NPG front brake kit. Poweder coating thanks to ctmystique.     I also test fit the up-pipe for the turbo today.       I also started working on my LC-1 Wideband O2 controller install today too. I deceided to route the O2 sensor cable through the bottom of the steering column seal. this way the unit can be placed under the center console right near all off the hookups.

BrApple

BrApple

 

loosing my mind already ....

well, I am loosing my mind some over this project, but I found it I think           went to put the AN hose ends on the turbo feed line last night and didn't ahve any luck. The ends are not made for steel braided hose from what I researched. So what I think I will do is just get some rubber hose and use that if needed while I order up a pre-made hose.       I finally got the maf situation figured out. The first one I receieved was infact a 80mm maf as I was looking for. Now I need to find a maf adaptor and possible some new couplers so I can put everything together. Also this is where I starting loosing my mind this morning. I got another maf today and it was suppose to be 80mm but it was larger then the one that I had. I then got mixed up on which was which. I found conflicting info on the web about what part number was what maf ..... took them to Gregs and compaired them to his 90mm maf and its all straightened out now. But because I can't install it I now have to hold off on my fuel system upgrades. This now puts everything behind.       So I changed direction late this afternoon. I started installing my NPG big brake kit. So as of right now I have the passanger front done. Tomorrow and will get the drivers front done and then see about the rear brakes. I need to go back and use some thread lock on everything as well as torque all the bolts also. Then I need to sand the pads so that they bed in nicely with the new rotors.       If I don't install the rear brake kit I will pull the y-pipe and test pipe so that I can get in there and install my LC-1 wide band controller. I think I am going with the idea of getting up behind the heat shield and just going through the floor to run the wiring. This way the control unit and connectors are in the cabin. At that point I will also start installing my turbo timer.

BrApple

BrApple

 

it has started

got a few things done tonight. First I drained and refilled the mtx with Ford "Honey" again. Next I went about mounting the FMIC onto the car. I also received my NGK TR6 sparkplugs today. Also thanks to ctmystique my NPG brake kits brakets are now powdercoated and ready to install.   Needless to say I have alot of work I want to do this weekend.          

BrApple

BrApple

 

small details

well last night was spend covering some small details. First up was to check for any leaks. Again there doesn't seem to be a problem, just oil left all over everything from the previous leaks and the half shaft miss-hap from over the weekend. Just to make sure I started checking bolts. I found some on the oil pan that tightened up alittle bit more then they where. But mind these where not loose, they where snug. next I moved around some wires in the area of the turbo and cleaned things up. The secondary ground to the trans was moved up and back, the old battery ground also got removed. I also pulled back the lower O2 sensor wires to get it awasy from the area also. I also tried to find some more hardware to attach the SVT undertray but didn't have any luck.   So up tonight I think I will drain and refill the mtx. right now there is a mix of Ford "Honey" and Syncromax. I want straight honey in the mtx as I was very pleased with it. Just need to get one more quart as I have 1.1 quarts already so I have the total needed of 2.1 quarts.   Also I came across something interesting. Another CEG member after installing his turbo ran it with the stock intake while he went to get the car tuned. I really want to start on my install and I can easily install all the hot pipes, turbo and oil drain feed so that everything would work but it wouldn't be feeding the engine. Really would love to do this but I think I want to stick to my original plan of getting the Fuel system upgraded and working correctly. So as long as I get my 80mm maf by the end of the week I should be all set on that front.   Also no matter how much I want to take the SeVT-T to SZ I will not rush any of this install. Actually this is the quickest I have done some installs of parts I have purchased. Like I had the MSDS headers for a year before they got installed. I have had my LC1 for a year at least and still haven't installed that either (but I tried last night but couldn't get the 02 sensor bung plug out ...). So between the 3L and the turbo this is the quickest I have gone about installing mods.

BrApple

BrApple

 

was all fixed ...

well this past weekend again provided to be an interesting weekend.   First up was another 3L swap for this weekend. Saturday we where able to pull the 2.5L and strip the engine down. Also we started to prep the 3L. When the owner came back we made him go buy new tires as all where shot and one was showing the metal bands. We also highly suggested front brakes and he decided to do all 4 corners. By the time I made it back Sunday the 3L was in and we just had to button up a few things and fire it up. Only issue was a brake pad that went in backwards which the owner did himself.   Sunday didn't go as well for me. I was heading over to meet up with friends for the CCSU car show when I am crusing along and I lose all drive power. The engine just free revs. I tried a few different gears and nothing. This was all after I heard what I thought was a rock bounce up under the car and didn't think anything of it. When I got to a stop I see the line of oil leading back from the car. Then I get under the car and oil is pooring out the the mtx. I thought the drain plug came out. I look closer and its coming from the passanger side axle seal. Great the seal popped or something in the trans popped and took the seal out. So I call a friend that I was meeting ans asked for a hammer and some ATF fluid, just to get me home. Well Then I look again and I see the half shaft doesn't seem to be in where it should be, the rust line isn't at the seal. I call my other friend and he metions checking the nuts on the half shaft as he didn't recall tightening them down when we changed the seals. So sure enough they are both gone and the half shaft pulled out the the trans, but not off the bracket completely. So I get the shaft back in and try it out ..... I have power again. I killed it right after that as to not run the mtx without fluid. So by that time another friend was able to come with the nuts for the half shaft from his car (isn't running, waiting for a 3L to go in) and tools so I can get going. Got lucky and the trans only took about 1 quart of Syncromax. Then all was good again and I continued to the car show.   So now I need to pick up one more quart of Ford Honey and drain and fill. I also need to double check for leaks today, hopefully everything is still good.

BrApple

BrApple

 

fixed?

well I believe that everything is ready to go now. I will find out in the morning.   This afternoon axles and seals where repalced with GCK axles and new oem seals.   Also it appears that the crank seal got folded in some. New crank seal and tensioner where also installed.   So the hope is that this will take care of the oil leaks that I have.   I also believe my walbro install kit arrived today. So once I get that and are able to install the maf and 42# injectors I will along with my tune. Once I am happy with that its turbo time

BrApple

BrApple

 

turbo setup ...

well first thing up last night was to finish my pre98 inner door conversion for lighted door handles. The drivers door went pretty quick. Only down side I have noticed is since I spliced into the window switches for ground and power the lights do a few odd things. If the window lock is turned on for the rear windows the lights will turn off. Also when I hold the drivers window switch down the light will turn off. I suppose I could ground it to the door instead of the switch to take car of that but I normally use the one touch feature so I don't think it will matter at the moment.   Next I moved onto setting up the turbo setup. I wanted to bolt everything together to just check things out. I ran into one issue, the maf adaptor I have doesn't fit the 80mm maf I plan to use. So I need to work that out now also. Luckly everything else went together as it should have. Now all I need to do is figure out all of the vacuum lines and the install should go very smoothly.        

BrApple

BrApple

 

weekend wrap up ...

I did alot, and didn't do alot this weekend. My projects more forward alittle but not much, I spent most of the time helping other with their projects.   Over Friday night and Saturday morning I detailed my gf's Civic. She made the poor choice of trying to wash teh car by putting soap and water on a towel and whipping the car down . She heard about that one from me. Anyway I got all the swirl marks out in two steps. First I took Z-CS (paint cleaner) and a medium cut pad on my PC to the car. I then follow up with Z-AIO and wow there was some shine there . Needless to say she didn't think it was her car after seeing it done.   I also started on my friends SVT yesterday. Again because of circumstance the car hasn't had much care paint wise. So I went to work and used the same process as above. I got some shine back from that paint also . It came out similar to my Mystqiue. You can still see swirl marks in the paint at certain angle and light but otherwise there is just shine. My friend was funny. He awas standing off to the side and comment on how as I polished the car I refelection of me in the paint started as an outline and then the color came in the more I worked the polish. I got that car about 80% done.   On the SeVT I started out on Friday, or was it Thursday by detailing about half the car. I took the PC to it with the Z-AIO. Once I get the whole thing done I plan to go back over with Z5 and Z2. Other then that while I was workign on y friends SVT he was working on replacing my fuel pump. I am upgrading to the Walbro 225 lph for my boosted application to ensure that I have the fuel needed. Well we ran into a problem. I only purchased a pump so it didn't have the electrical jumper nor filter sock for the pump , so back in went the stock one. So now I need to find an install kit or just order a whole new setup and sell the pump that I have.   The other thing I did this weekend was help another friend for a few hours swap out his interior in his SVT. He went from prarie tan to midnight blue in his T-red SVT.   So this week I need to install my LC-1 wideband O2 Sensor. I also have new axle seals and crank seal to be installed to stop fluid leaks as well as new axles. I also ordered a turbo timer that will need to be isntalled to.

BrApple

BrApple

 

more on the SVT

well today was another good day. Not only was the weather good but I got more work done on the SVT. First up this morning after dropping off used oil was to wire up the oil pressure and a/f guages. So i was able to run the two wires for the guages but I was not able to make both work. The A/F guages was simple enough to make work, just soldered the wire into the harness. However I was not able to remove the plug from the oil galley in the head, didn't have the right tools with me. I know this isn't the best location to install the sender but it will tell me if I have oil pressure or not. I still have to deside if I will get a remote oil filter kit and put the sensor over there. After taking a break to take care of some family business I had a friend and fellow CEG member install my Ford add on alarm. He did a very nice job and got it done in about an hour and a half, where as it would have taken me alot longer.     now the hard choice, when I head home tomorrow what car do I take ... its suppose to be nice all week again and I really enjoyed driving the SVT this week ....

BrApple

BrApple

 

busy evening

well ... with the temps almost at 70 it was a great afternoon and I got a number of things done.   I was able to take the SeVT out for a drive which is always fun. I also swapped out the passanger rear door inner handle so i could install my green leds to light the handle area up. So the backs are now done and the front still need to be done.   As for the SVT I got a number of things done. Since I had all my detailing supplies I started to go to town. After I had gotten it I detailed the car with Zaino but doing this by hand I put a number of swirls in the paint. You couldn't see them all the time except in certain sun light. The Porter Cable took them right out, it took great paint and made it better. All I used was the Z-AIO which has some like cleaners in it with a polish pad. I didn't do everything but I did get most of the car done. I then went about getting my guage pod wired up. Just about everything is now working. All I need to do now is run the A/F guage and oil pressure guage signal wires into the engine bay and connect them. Its nice to see it working after looking at it all week with it not doing anything.

BrApple

BrApple

 

SVT Mods

well the little tweeks to the SVT continue. Yesterday after work I was able to install the B&M shifter that I had. The shfting and shift feel is 100% better. Man how I hate that stock shifter. Although the B&M is alittle short for me so somewhere in the future I will be installing my Steeda Tri-ax shifter I originally picked up for the SVT. I also started my factory add on alarm install by mounting the valet/indicator switch and the override switch. So today after work I hope to either start wiring up my guage pod to make everything work or take the SeVT out for a drive and check things over there.

BrApple

BrApple

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