My project thread(bodywork, turbo, suspension....everything)

[Afliction523]

Hey guys Im sure you have seen my prior threads with some bodywork as well as starting the turbo installation on my ka24de. I am now almost comlete with the car. This car was bought in Oct. 06. It is a 92 240sx coupe. The car was oringinaly a automatic when I purchased it. I bought it for 1100 dollars, and have invested a decent peny since then, but as one knows once you start buying stuff you will keep going and going.(this project may never end) This car is not a daily driver, but a fun weekend car. I will not drive it in the snow or rain, and the car no longer has any emissions components left on the vehicle. Enjoy the pics.



My first day of bodyworkThe car had grey metalic paint (macco) It was in poor condition. I decided to start with the fron fender and work my way back

OCT 06

I had to much fun with the grinder (had low spots)

Filler Primer

My new transmission to swap in

Its a cold November in the grarage working on removing the damn auto transmission.



Well the front cover or the transmission broke so I bought a new one

Back To body workMar 07I got a nice day out and decided to get some work done.I have totally deleted the upper body line of the car, and removed teh antennea on the rear of the vehicle



The other side

TURBO TIMEDitched the front bumper (buying a new one or bodykit...have not decided what to go with yet so for now tossed it and installed a intercooler for the turbo)InjectorsOil Pan

[Afliction523]

TURBO TURBO TURBO

Installation(almost done)

This what I have done as of now, tomorrow hopefully get the old exhaust off and get the intercooler hot pipe fitted. I want to get the wastgate vac lines ran and my hks ssqv installed. More pics to come guys.

[gaehrings13]

Man a lot of great work, but if i were you I would NOT! use that manifold, i have the same one and it cracked twice and I had it tig welded the first time. Then I went crazy with the mig and it has been holding up. Then the thread on the turbo flange were starting to mess up. I dunno but im going to try to get the cast revhard one so I don't have to change so much because I had to use a oncenter turbo to clear the mbc. But hey your setup looks good and clean.

Im going to do my 5spd swap soon so I will be able to tell you guys the difference going from kat auto to kat mt. Trust me the auto sucks, I hate the way the rpms stay so high on top end.

Even though the car is fast on 1st and 2nd and on the highway its great, it take nothing to over past a car, i just hate the way the automatic kicks down lol when i don't want it to. Lol it still thinks it NA.

Trust me you will be happy when that car is tuned and ready to go Ka's feel great.

[Afliction523]

I know the manifold is risky. The only reason I went with it was the price, and that my boss has a vr4 gallant...he has used it for 2 years and nothing has gone wrong. I hope it holds up, if not I learned my lesson. Like I said before, its not my daily but we will see how it goes. It looks good, but I know that I have seen better. The only thing I am worried about is boost creep from the placement of the wastegate. I appreciate the comments man. The car has been a pretty fun project, and a HUGE learning experience.

[Afliction523]

I got all the turbo parts in ...but it wouldnt start. I realized I mixed up two of my fuel lines after I took all my wiring apart for my injectors and maf. I got it started and wow I cant wait to drive it. I still need to neaten up a few things with the install, and weld up the outlet to the downpipe but all looks good so far. Tomorrow night after work Ill put some new pics up. I want to give a shout out to Drape123, this guy burned my ecu, and I was sceptical. It seems to be working good so far. He seems like a stand up guy. Ill take it out for a drive and be sure to let everyone know. Im ofically KA-T

[gaehrings13]

i have a 5.8 lb spring in my wastegate with that mani and its boosting 9lbs. So watch you boost gauge carefully.

[babowc]

how many coats of filler primer did you apply to get rid of the dips/pits?

i am working on my hatch right now.. i too gota little happy with the grinder and made bunch of scores in the hatch..lmk\looks great tho!

[Afliction523]

I used spot putty for the dips or divits in my first sanding. I then used two coats of filler primer(duplicolor) where neccessary. I wet sanded the filler primer, be prepaired to have some extra sand paper this stuff clogs easy. I then applied two to three very light coats of black primer. I will be getting the car painted flat black and that will seal everything in. Good luck with the car, I hope this helps

[eazye2000]

Effin' Smooth Coupe!!

I still love my hatch, but that Coupe is sexxxy...

Good work man, and keep it up. I'm a big fan of pictures!

[hannibal]

Good work man! I'm secretly scared of bodywork.

Good luck with the turbo install...

[Afliction523]

Thanks eazye2000, and hannibal. The car is smoking a bit, so I will save the pics untill i install the restrictor which should be here in the next few days. I took it for its fist drive with teh turbo.....WOW This thing is quick and throws you in your seat like no other. To bad I only made it down the block, turned around and shut the car off because of fear of blowing my oil seals. KA-T is fu&K*ng awsome....I have been in a sr20, and driven one....got nothing on this. Best part is 15lb on this setup should get me over the 300whp mark and I cant wait to really get on the pedal.

[Afliction523]

Well Im still waiting on the restrictor. Here is another pic from tonight. I have my intercooler, HKS SSQV, and Z32MAF/Air Filter on.

I still need to neaten up the engine bay, and clean it after the restrictor comes.

[WDRacing]

If you mean a restrictor for the turbo supply line you don't need it. Unless your oil pressure goes over 70PSI you're restricting it to much. I've never used a restrictor on any of my turbo cars unless the turbo was a ball bearing center cartridge which yours is not.

Awsome thread and great pictures. I look forward to this progressing into a really nice project.

WD

[Afliction523]

I was told I should use one. I started the car once and it burned oil past the rear seal. I took off the return line, and let it drain straight down and had minimal oil come out when the car was off. That led me to beleive that it is returning fine. I looked in the top of the turbo with the feed line off and the oil was taking forever to make it back down which made me think I am giving it too much oil. Do you have any ideas with this? Jgs reccomends it over 50psi. I also heard that this turbo only needs 30psi to be safe. I hope I dont have bad seals since I bought this turbo fully rebuilt from another member on this forum. I beleive it was dammitboy. Here is the threadhttp://forums.nicoclub.com/zerothread?id=231099

[WDRacing]

Is your return line straight? Sharp bends may cause oil to back up.

[Afliction523]

The line is straight with a light swooping curve into the oil pan. I used the jgs kit for feed and return. I checked my oil level and removed the return line. It all seems good. Should I try a 45deg. fitting or even a 90degree fitting at the pan? I had the turbo checked before I put it on and was told it looked good. Now im a little nervous I only got to run the car into 3rd gear and only doing 4lb of boost . I hope I dont need a turbo rebuild already. btw i appreciate the help and the positive comments so far.

EDITI pulled the oil line off and there was no build up in it that i could see. I did it immediately after teh car was ran.

[WDRacing]

Well every book I've read has always said a restrictor is the last resort. An openly flowing oil return, where the oil pan is tapped above the oil level should never back up.

Here, read number 16.

http://www.turbobygarrett.com/...l#t16

[Afliction523]

I hope I have some sort of exteme oil pressure for some reason. I have a pic in this post with the oil pan near the top of the page when I started showing pics of my turbo. It is the highest I could go, and modeled off the ka-t dvd from JDS.

[Afliction523]

Thanks for your help. Im off to go work on the car. I need to mock up the outlet and piping to meet the sr20 downpipe i purchased. I also need to start wiring my guages. I guess I can only hope this oil issue is taken care of with the restrictor.

[WDRacing]

Well, if it smokes you definitly have other issues...lol.

[Afliction523]

Ok, I need to figure this out. I put in the restrictor. It seemed to smoke less and then nothing. (just started it) I drove it down the block, it warmed up and poof smoke. Do you have a good pic of a proper oil return line. My oil pan is tapped in the proper place. That I am sure of. The bung however is not perfectly straight. It faces the ground slightly. (barely) . Could that little bit be causing back up? I also noticed that if I take the return off and let it drain into a pan, a little oil comes out. I look at teh top of the turbo where the feed is, I remove it, and i see oil still in the turbo. Shouldnt it drain faster. If I pull off the retun and run it oil should be dumping right out the return? I havent tried that yet, but figured that would be a good way to start. BTW I have zero shaft play side to side, or front to back. I dont know if that helps any. I appreciate your help.Thank You

[Afliction523]

Ok , i remove my return line and oil came out of the line it self. I think someone has a bad return....i hope.... It actually spewed out for a second. ( My car was not on during this)