My s13 race project. Alot of pictures.

[staff]

Hi!

First of all, Im from sweden and im bad at English. And I hope you can stand the bad spelling. Pictures says more then words, so ill try keeping my self to pictures.. hehe

This is the second phase of the project. When I bought the car it was in real bad shape, the chassi was destroid by rust, so alot of work have bin put into changed old metall etc.. Then I build an engine, forged internals, custom camshafts etc.. I ran with a sc61 and about 1,5bars of boost last year. This was just a trail year, and now its time fore phase 2. Making the car just as I want it.

Some nice cutting made to the front. Nice and clean heheIt can be boring cutting metall by hand, but its a good way to make it right.The new bits are starting to take place.Some welding to make it stay in place.Bad photo hehe

I think it lookes great.Now its just to make the other side the same It takes time to make the peaces fit.

As I said, All of the parts have bin taken out of the car again. This saves time when we are fabrucating. And the interior needs a real paint job.

I had a gas leak thats why it lookes so :down:

The collector fore the exhuast manifold are done.

Comming together nice.Still have some finishing work to do. But its almost done.

All the small holes fore bolts etc, have bin welded and grinded down.

We have taken out the front window. So its alot easier to work with the car. The last part that will go back on are the windows.

Ive started to do some work to the new head, wich im going to use next year. I will still be using the same custom camshafts and my homemade solid lifters in this head.

The body are almost done in the front.

The block is horned and have bin fitted with Piano thread to hold the presure in place. I ran up to 2bars with the same setup and standard headgasket this year and that hold together. So I hope to have the same results next year!

My standard gearbox brooke after some race track laps. So I will make an adapater plate to use a z32 gearbox.

Some parts that will be used on the car.

I decided to build a manifold. So I bolted the front subframe back into the car with engine mounts. Put a cylinderblock and head in it aswell. Then I made a new jig fore the turbo and started to build the manifold.



After I was done with the tubes that could hit something. I lifted the block and head onto table instead. Much easier to work that way!

After some hours of hard work the manifold was done. As you can see I have decided to use long pipes, at first I was going to use short pipes to get better spool. But after doing more reading and checking testing of manifolds I decided that this will be better fore my engine. Now I only have to tig weld it when I get some time over!

But something els have starting to take form in the car. I will have a big IC and oilcooler in the front wich will need good airflow. And I want more weight in the back. Thats why I decided to move the radiator to right above the rear axel

The front cover fore the radiator is finished. It will run a big hose on each side with fans in them that will suck air from under the car into the radiator. Then another big fan will suck it pass the radiator and out the rear.

The rear tunnel is begun but its alot of work done untill its finished.







Took some work and aluminium to get it complete.

This is just the begining, it will be fitted nice and the cut open

Always fun to start cutting and welding in new painted parts!

Also, I have started doing some filling work.

Ive tig welded the exhaust manifold, It takes alot of time to weld stainless steal because you have to tape the manifold so its seald off everywhere but the part wich your welding. This is because to get a good weld on the inside of the pipe you have to fill the manifold with gas, I use MISON AR. This is to get rid off the oxigen(?) in the air. Wich will cause alot of "dirt" in the weld.

Since I was alone while doing this I couldent get any action shots with the welder

Then I took a cylinder block and mounted it in the car with a head, then I mounted manifold, turbo and intake. About the intakeplenum I would like to make a new and smaller one. But It will be hard to find time fore it..

Ive starting to figure out how to mount the IC, I would like to have it in the engine room to get short IC piping. But It will be hard to get nice flowing piping. So I will mount the front spoiler(these is why I have mounted the fenders again) to see if I can get it to work down there. This will leave me with a clean and empty engine room.



It takes some time to get the ic nice and center.

Made new aluminium ic pipes. And started rebuilding my intake manifold.





I drilled holes on the other side fore the IC piping. If you dont have the right tool fore the job... improvice Did the same on the first side.

I also cut and fitted the peaces fore the lower side of the cold pipe. And I orderd some new piping and hosing from PPF. So I hope to have the ic piping all welded and done before next weekend.

I placed and made mountings fore the oilcooler. Gonna make two more mounts.





The cold ic pipe are done, but I havent welded it yet. I might redo it later on anyway. Having new ideas hehe..

The engine block and head etc Have bin lifted out again. And the body work have started again. Welded more holes in the firewall, and I bin sanding the filling to make it ready fore paint. I hate this, it gets so much dust over everything in the garage.. So ill try to get all of the sanding done this week so I can lay down a basecoat and then go on with the interior.



Well thats about it fore now, this is where im at today.

Hope you find it intressting!//Staffan
Modified by staff at 7:33 AM 2/28/2007

[le_ryan]

wow, nice, you got some skillz there homie !definatly keep us updated, what kinda racing are you doing?

[amolao]

Good work, gotta love fabrication. Oh and welcome to NICO...

[karmakaze]

Good work, gotta love fabrication. Oh and welcome to NICO...

awsome job!

[mrgreeneyes]

nice work man. thats a lot of work and dedication man.

[rico05]

You Swedes don't do anything half way do you? Seriously, I have seen more awesome cars come out of Sweden than any other country next to Germany (sorry).

Amazing project. Great work. Please keep us updated on your progress!!

[bone_stock_240]

You are my hero. Awesome work. Want to take on an apprentice? hahaha

[slik_s13]

keep us updated for sure. i enjoy seeing your work in progress.

[amolao]

This is in the same tradition as the famous internet guys redoing the 240Z, also from Sweden, I'm not mistaken...

[Eikon]

That's the best first post ever!!!

Nice work staff!

I wonder if you live anywhere near Swedish Mike... he's a member here who hails from Sweden.

[thomasjamal]

Wow. Can't wait to see more.

[chrislis]

wow. great work man. mucho high fives your way.

[srpowered240sx]

Wow. Can't wait to see more.

my sentiments exactly.

[white90esex]

Looks cool man. I wish i had all those tools at my disposal.

[forksquared]

omfg amazing bro!

[Dragon13]

Fantastic bro, I am sure alot of us are wishing we could do half of the work you have been. I know I do anyways. Keep up the good work and keep us posted.

[Terran]

That is one crazy radiator.

[jdm_master_X]

its posts like these that inspire most of us go beyond the normal project.

excellent work and welcome to NICO!

we dont mind your spelling because you speak better english than some of the folks who actually live here! hahaha

[Driftless240]

That's the best first post ever!!!

I second that. Awesome work and I hope you keep us updated. You'd better because I am going to be checking in alot to see. Also do not worry about your english, as stated, you speek it better then most of the members here.

[r34 gtr]

you win at life. seriously, i couldnt even try and do all that. i want to though...

[Matej]

Nice, props to you!

[yessir240]

man o man. oneday i will have the time and funds to do this.. Great work man keep us posted!

[Bwana]

Holy Cow!!!

BEST FIRST POST EVER!

Welcome to NICO!!!

What kind of power are you putting down with that CA?

[bt2s14]

Pretty amazing work you have done there, keep us updated

What kind of power are you putting down with that CA?

[AmoebAssassin]

Gorgeous build, good luck with it!

[Jiggyfry]

REALLy nice work Staff! And welcome to Nico!

Im goin to change my pants now....

[sicride]

Wow this is an amazing first post, and you've done some excellent work. I just have a few questions, hoping I can learn something.

What was the purpose of the inner fender modifications? Do you plan on running your car so low that you needed more room? What size tires are you running and what suspension that will allow the car to not bottom out and have enough travel to risk rubbing?

Your valve seat grinding, I know little about how this is usually done but I expected it to be more "machining" than hand done. How did you make sure the valves are going to seat fully and seal?

Where is the air from the radiator coming in and exiting? I could not see clearly how you were doing this. I've only seen one other 240 personally that has done this and it did not look efficient. Have you thought of the possible aero results of this? Sounds like you might be causing some lift at high speeds or atleast losing some downforce.

All just curiousity. Can't wait to see the results.

[whiterps13]

Damn bro, you have some serious skills to be doing all of that stuff by yourself. Good luck with everything, you obviously know what youre doing.

[Got240]

SICK!!! i wish i could do that with my 240.....what are you planning on doing with it Drift, drag, autocross????

[staff]

Thanks fore all of you comments! I dident expect this much respons.

If you have anything more you would like to know just ask, and ill try to give a good respons as I can.

What car does “Swedish Mike” drive? Maybe ive seen him on swedish sites..

About the question of what type of racing ill do. The car is buildt fore trackdays, we have some real great events where a lot of fast cars enters. A lot of car clubs have there own track day on a race track about 100km from where I live. So ill try to race there as often as I can. Then we go to events in Norway, cald Gatebil. It’s a fun event, and they have a race class “gatebil extreme” wich I hope to enter late this year ore next year when all small problems have bin figured out. Ill also have some fun driving it on the streets aswell.

When I looked at my inner fenders it looked like I had some tyre rubbing on them. Running with tein coilovers and 18” rims. But the main reason I rebuilt is that my innerfenders was in bad shape, dented. So it’s a good way to get a good looking inner fender instead of repairing the old ones.

I havent done the valve grinding yet, on the pictures I have just removed the squish areas and im porting the throat etc. More information about valve and seat cutting will be posted when Im doing that work. It will be done with machines yes. I think that theres hand controlled valveseats cutter in the market. I read about that in a book ones, but Im not skilled enough to use one of those.

The air will be sucked out of two big hoses from the floor of the car. And exiting out betwin the rear light. Three fans will be used, two in each hose and one at the rear of the radiator. Im not sure my self that this will work, but I go by trial and error. I don’t think that it will cause problem with downforce because im getter rid of air from under the car. If this dosent work ill try to replce the rear windows with lexanglas and drawing air from them down to the radiator. And see if this workes better. Something like this.

About the engine, the goal is to put out about 500-550bhp without race fuel. I think that I will run on the fuel e85. Don’t know if you guys have it in the states? It’s a mix of ethanol(?don’t know the word) and some gasoline I think. This fuel can stand a lot more boost and ignition without causing DET.

The engine that I built and used this year had some problems during tuning. Not because of massive power but failing sparkplugs. We where hitting 2bars and all of a sudden the turbo pressure went down and the car stoped reving. A lot of smoke.. we first thought it was the engine, then after removing air filter and taking a look at the turbo we saw that it was broken. It seamd like the axel had broken straight of.

The next day I took the turbo of, finding that the axel had broken. At first we thought that it was a fabrication error. And the tuning shop that I bought it from here in Sweden stept up and send me a new turbo. This was a garette gt30bb r 0,82ar. Because they dident have any SC61 turbos in stock. Then I sent them my broken turbo so that they could find out if there was a warrenty fault on it.

Here you can see my old blacksteal manifold. It was heatcoated after welding. Worked good, no rust.









When I gut my new turbo on (after a lot of work) It did not fit with my manifold without moving the master brakecylinder and brake servo more to the left. I saw that two of my sparkplugs was broken and missing some peaces. I gut a bit worrid about this. But I did a compression test and it looked good so I thought that it would be alright(I was wrong). With the new turbo the car dident feal as fast as before. And it had a big turbo lag, and this was with a turbo wich should have better spoolup then my old one.

Any ways, in septermber –06 we went to a Gatebil in norway. Had a lot of fun, drove with 1,5-1,6bars boost just to be safe. This was the last race event fore me this year. I had planes of taking out and making sure that the engine was not damaged. And to started the fine tuning fore next year. But it ended in an expensive way.

Pictures from the last race event. My brothers z32 in front, he runs with a ls1 engine and a 6speed tremec gearbox.





After a few hours, we had bin taking a break in the pit. Then when we gut back onto the track I just made it a half lap and then the engine temp was real high and the car started to sound real bad. Went back to the pit, loaded it onto the transport and had fun watching the other cars the rest of the day.

The next day me and my little brother took out the engine. We thought that it was the main bearings that where broke. But it was more to it then that.









After taking the head of we found that the pistons was damaged. Im not sure but I think that these damage was made when the sparkplugs broke. Parts wich had to be scraped was, the pistons wiseco forged ones, one eagle rod, the crank, cylinder head.

So fore this I have order custom JE pistons with 8:1 in compression and I ported a new head, this time I have removed the squish areas. To make it easier to handle high boost. Almost everything will be changed on the engine, I sold the turbo, manifold, ic, dp etc..But ill still run with the same intake, camshafts and valve lifters. I will document all of the parts going into the engine and the tuning phase will be documented aswell. And since you guys have shown this much intress in my project I promise to keep you posted. But fore now its just boring filling and grinding work that going on. But I hope to make my head ready in about two weeks. Then it startes to get intressting again.

I hope I dident bore you guys with my long respons.. But im at home from work sick right now and I since I cant build on my car with high fever so I gut a lot of time over today hehe, I hope to start the work again this weekend.

Thanks again fore the show of intrest!!!

//Staffan