Project Update....

[LongIsland240]

Been a little while, but for those of you that give a crap:The KAT is just about assembled and ready to drop back in. Since the last update, Pauter rods have been thrown in the mix, as well as a new T3/T40E, and gasket matched and ported head/intakes. Just have to bolt on the covers, install, run new piping for the huge intercooler i replaced my starion core with, and relocate the battery. Should have her running by early next week. Looking for 280whp @ 10psi with my current fuel setup, and eventually want to boost this thing to 20-25psi or so. I spared no expense while building this thing back up, hopefully it doesn't disappoint. Will keep you all posted.

[SlidnSideways]

Sounds like it will be alot of fun. Post up the results when you get it done. I CANT WAIT!

--Tim--

[Florida240sx]

Awesome, hope it turns out like you want.Got your setup posted somewhere?

[Craving4Boost]

good job man that thing sounds like it's gonna be bad a**

[turbo98_240sx]

Disappoint is one thing I bet it does not do, seriously that's sounding like its gonna be a killer setup

[Checkered-Member]

A short engine mod list please...thank you

[LongIsland240]

Sorry to be digging up the dead...but as I sit here tokin this bowl of fine herb, I see many familiar faces around here. Cool man, cool.

To finish the post I left hanging back in '05 :

The KAT ran great for about 1000 miles, and the first time I really stood on her, I spun # 3 rod bearing. Tore her up bad. Disgusted...and quite broke, I was forced to let her sit for the last 3 years. I tried my best to forget about her, but always swore she would be back just as soon as life allowed.

The time has come.

I pulled her apart and surveyed the damage, actually much worse than I hoped. Crank and #3 rod...ruined. Head.....ouch. Several thousand $$ later, I've got a whole slew of new parts to go at this again. Should be coming together over the next few weeks/months. I'll get pics up and such for those interested.

I got to sit in her loading up on the flatbed to work...nearly cried. Can't wait to be in my 240 again...damn VW smells like an old barn.

Seems like KATs are a lot more pletiful these days, it's good to be back.

[480sx]

Weird failure man, you ever figure out what happened? Your oil full of gas or somethin?

Anyway, good to see an old g tryen to get back into the game, GL man and keep us updated.

[neverlift]

that is a strange deal you got stuck with man, glad to see yah back at least

[LongIsland240]

As far as I can tell from the partial motor teardown (to be completed thursday), It looks like the a$$ who did my machining made the bores a bit too tight for the old slugs. I've got some obvious rubs on the cylinder walls from the piston skirts. Other than that, no other issues were found.

The car is all torn apart at the VW dealer I work for, so when I pulled the engine it went on a stand and I left it basically in tact so it was less parts to keep track of. Since I have the whole day off thursday, I'll finish popping out the pistons, crank and studs. Then take the block down to the machine shop we use to see if my cylinders can be saved, or if I need a new block too...at this point, it's the only thing I'm re-using.

Strange deal indeed.....I tear apart VW engines that make the KA look like an erector set everyday, and they don't break. I'm pretty sure god hates me.

[kouki_hmongster]

That really sucks, you have to put everything on and then tear it apart. that is a lot of work. i would go crazy and kill the machinist. lol

GL

[WDRacing]

Sorry to be digging up the dead...but as I sit here tokin this bowl of fine herb, I see many familiar faces around here. Cool man, cool.

To finish the post I left hanging back in '05 :

The KAT ran great for about 1000 miles, and the first time I really stood on her, I spun # 3 rod bearing. Tore her up bad. Disgusted...and quite broke, I was forced to let her sit for the last 3 years. I tried my best to forget about her, but always swore she would be back just as soon as life allowed.

The time has come.

I pulled her apart and surveyed the damage, actually much worse than I hoped. Crank and #3 rod...ruined. Head.....ouch. Several thousand $$ later, I've got a whole slew of new parts to go at this again. Should be coming together over the next few weeks/months. I'll get pics up and such for those interested.

I got to sit in her loading up on the flatbed to work...nearly cried. Can't wait to be in my 240 again...damn VW smells like an old barn.

Seems like KATs are a lot more pletiful these days, it's good to be back.

Sounds like what happened to me, cept I tossed a rod through the block and she's still sitting. I'll be fixing her one of these days...

[LongIsland240]

Well, finished tearing the motor apart today. Other than the spun bearing in #3, the rest of the motor looked decent. None of the other bearings wore into metal. Took out the studs and the block went to the machine shop, just have to wait for a verdict from him on how my cylinders are. (Crossing fingers for 89.5mm)

For the build so far this time I've got:

Another set of Pauter RodsRoss Pistons w/OE Rings New CrankshaftRebuilt Port+Polished Cylinder head with Ferrea Valves/Springs stock S13 camsACL Bearings - Calico coatedNew OE Timing Chains/Guides/TensionersOE Head Gasket- Screw Cometic....Same T3/T4 as last time750cc InjectorsZ32 MAFECU went to Jason for tuning todayMore crap I can't recall...

Wonder if the A/C still works??

[LongIsland240]

It's taken much longer than anticipated....to say the least. She's probably going to start this weekend.... /knocks on wood

Actually, you can pretty much scrap that list of parts. I ended up going with 100% new, or re-machined internals, instead of the used stuff I had bought. When I got the pistons and rods they were quite abuse and partially melted (piston tops), so I bought some eagle rods and wiseco 9:1 90mm pistons.

I did get the used head with all those nice springs and titanium parts, had it checked top to bottom and shaved .002", just to have a fresh surface...and match the timing cover. I went with a copper head gasket at .054", just to make up for the head and block being milled. As a side note on the copper HG, it does NOT compress at all. Even after torquing down all the nuts, easily got .054" of feeler gauge in the gap.

The guy with the bearings kept screwing me around, so I finally got my money back from him and just went with some un-coated ones. The crank was cut, polished, and the whole rotating assy balanced by a competent machinist.

I rewired the car last weekend, put in the tuned manual ECM and engine harness. Also removed all traces of the automatic harness and control module. Cleaned up my remote battery connections, and wired the SAFC back into the new harness.

Tomorrow I just have to finish up the oil lines- got another ss line to remote mount my oil pressure sender....why do they make the damn things so big anyways?

More to come...

[LongIsland240]

Here she is up on stands- all back in one piece....mostly.



New harness in...and my favorite part, sexy bolt down wire loom cover (mine was broken). The un-corroded injector wires without the broken insulation are probably the more important part though.

[airman86]

i love those wheels. what are they?

i sure hope my ka-t project doesn't take this long /knock on wood

anyways, keep on truckin!

[LongIsland240]

The wheels were a set of Icons I picked up real cheap when I used to work at pep boys...*shudder* The Z calipers just fit

I got her running today, but pig rich. My wideband is showing 10.8 at idle. I need to just double check everything in there, make sure i didn't forget to connect something. No leaks, and the motor sounds nice and quiet, tuning we can fix. I may just bite the bullet and have the local nissan guy do it from scratch if it really is just a crappy emance tune causing it.

[NateDogg]

Try looking at the MAFS wiring/connection/placement.

[LongIsland240]

I double checked the wiring, it was good. Jason got back to me real quick, and I just had something set wrong. Idles much better now, feels like she needs to go for a good run. Gotta go to the DMV and such first though.

Re-wired all my gauges and installed a new Oil pressure gauge, and EGT in the center vent spot. I used in-wall speaker wire with 4 insulated 18ga wires inside for all the gauges power and signals. All routed through a connector strip screwed into the A/C duct way up under the dash. Just waiting on my vent pod to finish the install 100%....but it looks so nice and clean now, clean wiring is important to me much more now than it used to be.

I've got some more pics up of the wiring and such, but I took a customer's car home tonight and I left my camera at work....in my car.