In the home stretch......

[egan]

..And I have one question about the Idle air line...

Is it better to hook up the idle line to the intake(after maf, before compressor), or is it better to hook it up to the cold pipe? I've seen both, but I don't know which is better. Any ideas?

honestly, i think you would be fine in either position as your IAC wont be seeing any boost at warmup/idle. id just put it on the cold pipe so its cleaner and easier.

im so jealous of all the tools you have! (i wish my dad was into fabrication/mechanics) we dont even have a welder!

i cant wait for you to get this thing running, i really want to see how the hacked maf works under boost! ive got the same thing im working on...z31 t3 w/ 370's, and saving the cost of a safc2 would be tremendous! i even have a friend with a lm1 i could borrow, so it seems were in the same position. but im at school so my car wont be finished for atleast a month.....and id rather you be the guiney pig than me haha, so hurry up and get it runnin!

[hysteria]

umm definitely put it on the boost side... if you put it anywhere else you will be losing pressure out of the idle air and iacv passages (a boost leak). you will damage or destroy your aicv if you put it on the intake side because air will be forcing its way out of the passage that will try to close after the car warms up. your turbo will have to work harder to make the same boost. there are a number of other detriments to everything running well if you put it anywhere other than the boost side... so put it in with the boost already!

[crzycav86]

Time for another update...

I have some good news... and some bad news. I'll start with the bad news.

When we were resurfacing the flange on the manifold, the manifold wasn't clamped down strong enough, and when the drill bit got to a certain point on the first pass, it knocked the manifold off of the mill. No real damage was done other than a few kinks on the flange, which won't really interfere.(They're outside of the gasket region)

Here's a picture of it:

Now for the good news... I've successfully complete the cutting/taping of the intake. Now it just has to be welded and the silicone couplers put in strategic areas so as to maximize adjustability... and then I'll nearly be done with the intake.

Here's what the engine bay will look like, more or less:



WOOT

[hysteria]

awesome. that's like the most room i have ever seen on the exhaust side of a ka. it looks like mine did... when i had the manifolds off. i think it's safe to say your not having clearance issues with the brake system. good work.

[crzycav86]

Most definitely.

But the bottom mount leads to other clearance problems, mainly the oil return line(which runs straight inbetween the motor mount) and the intake.

I'm pretty sure that I've solved these issues, but we can't really tell until the whole project is finished.... who knows when that'll be though....

[hysteria]

it looks like it's coming along nicely, so just keep at it and you'll be done before you know it. good luck

[ShadowKnight006]

crzycav, what kind of/rated welder are you using on the manifold, if you don't mind me asking? I want to weld one up for my car someday but I fear our welder might not be enough.
Modified by ShadowKnight006 at 2:32 AM 4/14/2005

[crzycav86]

Hey. Sorry for the long delay. Here are the specs on the welder:

Millermatic 185 wire weldervolts 20(I think)amps 150duty cycle 60%max ocv 33amp range 30-185

[ShadowKnight006]

hey thanks, I will run that by what the one we have here says and see how they compare. I appreciate the info.

[crzycav86]

Hello all. After over a month of no updates, I've finally got a few things to share...

First of all, I sold out and had a shop resurface the flange. They did a good job.

Second, I finished porting the exhaust manifold to my satisfaction.

Third(latest update), I bolted on the manifold/turbo, hooked up the oil lines, and started the car. Here come the problems:

I primed the turbo for about 25 seconds before starting the car. The car started right up, and idled just fine, but there was a loud, LOUD screeching noise.... At first I thought it was just the belts, but when the sound didn't go away, I figured the turbo was blown. What made me turn the engine off, however, was the leaking oil feed lines. They were leaking from the connections at the oil pressure sender and at the turbo flange. I did not notice oil coming from the return line, but the engine was on for less than 30 seconds.

Now, about that screeching noise....

Is the turbo really blown? There is a bit of play in the shaft, and I could hear a slight metal on metal sound when I spun it with my hand. The loud screeching noise seemed to confirm these inklings of failure.

What are my options with this blown turbo? I prefer to get a rebuild kit, but I will buy another turbo if it seems more reasonable.

Thanks for your help.

[Craving4Boost]

if you really like your turbo, a rebuild is about 200$?? well that's how much i can get it for. once you rebuild it's basically good as new

[crzycav86]

Yeah.. I'm leaning more toward a rebuild. ...done by a professional!

[crzycav86]

Good news. It seems like I spoke too soon on my blown turbo issue. I tightened the belts and the screeching noise stopped. Yesterday I could have sworn that it was the turbo.

I also reinstalled the turbo oil lines and gave it an oil change. Unfortunately, I lost the key, so I didn't get to check my progress.

It looks like I'm back in business.... a good day indeed.

[crzycav86]

Back from the dead... and you all probably thought I scrapped the project.

Well... it looks like I'm just about finished with my kat project.

Yesterday I rattle-canned the IC piping, today I installed and clamped everything down. Then I started the car. It fired right up and idled perfectly. After it got warmed up, I backed it down off of the rollers and made a few passes up and down the alley....

......

It was quite a new experience. Over 3 months went by without driving the car. Boost comes on at 2500, and after that, first gear comes to an end in a snap. I only drove it for a few minutes, but those few minutes will be in my memory forever.

Today was not without its share of problems, however. It came to my attention that I have a pretty massive oil leak. I saw it coming because my oil return line is pretty crappy.. I just wanted to ignore it and hope nothing would happen. Wrong I was.

Another minor problem: the bypass valve is having some hood clearance issues. It's an easy fix, but still a problem.

After fixing those two apparent problems, I'll work on fabricating the exhaust... After everything is finished, I'll toss the wideband on and see what I can do about getting good a/f.

I decided to spare you all the crappy camera phone pictures. That means I'll post up good pictures taken with a digital camera tommorow or monday.

exciting times.......

[Checkered-Member]

Q:How come it took so long to get everything working, it sounds like you had all the components and tools.

Good to hear you are making progress

Another question, you said you are using an adjustable hacked maf, how do you adjust it?

[crzycav86]

Well, until summer came around, I could only work on it about every other Saturday for a few hours. When school was finally over, I could work on it all day, but the car is outside.. and the heat index is over 100 degrees every day. The weather isn't helping at all. Also, this is my first time building and installing a turbo kit. There are mistakes and problems that first timers come across.

There's probably several other reasons as to why I couldn't finish sooner, but it doesn't matter. All that matters is that I'm nearly done.

The adjustable maf works by turning two bolts that block the air flow through the sensor element. I made another thread with pictures. Do a search in this forum for "s13 hacked maf"

[egan]

holy crap!! so the s13 hack works????? how is the driveabiliy and how does it feel??? you took it to redline and all right? give us some feedback about it please!

[hannibal]

Glad you got to take it for a spin. Who cares how long the car was down? I'm sure it was worth it.

[crzycav86]

holy crap!! so the s13 hack works????? how is the driveabiliy and how does it feel??? you took it to redline and all right? give us some feedback about it please!

Actually, I haven't really tested it out. When I was still NA, I put the injectors on, and "tuned" the maf with an a/f gauge.

When I drove the car yesterday, I didn't use the wideband to tune, I just did a few pulls out of excitement. For all I know, I could have been running lean. Perhaps I'll put the wideband on tommorow and do a little tuning, but I really have to fix the oil leak first.

[crzycav86]

Engine bay..

Left side...

Right side...

Turbo shot...

The car...

My work area(100 degree heat.. y0)...

[koukiKA240]

ur work area kicks ***, the setup looks good, my only concern is your bov routed through the pcv vent. Dont think its good for that pressure to hit that so fast. Make that a direct shot to the intake pipe and go to ur local parts house and get u a ricer breather filter.~Sam

Is that a new ABS unit i see under the hood? wow.

[crzycav86]

Yeah.. I didn't wanna have two nasty hoses running across the front of the motor.

I'll probably just put a breather filter on it.

Oh.. and my car has always had abs... until I put the z32 vlsd in. Then it got disactivated. I've got all the weight of the abs, but no abs.

[crzycav86]

One advantage that I saw with the pcv placement is that at idle, the bosch bov will be open. So the blowby that passes through the pcv breather will go through the bov, and not through the turbo

[pr240sx]

Nice wastegate paper clip retainer!!!

Good work!!NOw get some boost and HP numbers for those in the process of doing the same!!