The Project Pad

As I wait for some parts that should be here soon... Figured to get a head start on the core issue that got me here...

The initial plan was just replace piston, hone and re-ring cylinder #5 ,.. but nah, the neighboring cylinder 4 could use some love to right?





Cylinder #5


My work area...


Soo far from ever being an FRP build cuz it's literally my backyard build... Back-Yard-Performance FTW!!!


15 Light Passes






Cleaned up the gasket mating area



30 More Passes at the firmest setting on the hone device...





That'll do for now on the block

On to the damage...
Piston #5






The new one that will replace it...


Piston #4








That's enough for a couple of hours of work this morning... I'll assemble the bottom end within the next 24-hours and maybe touch it up with another couple layers of paint.

Wow Piston #4 was ill aswell !

Great paint, I like the color !

And they're in...

Nice! Looking forward to vids

chaloux wrote:Nice! Looking forward to vids

Meeeeeeee Toooooooo

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OB - A true inspiration.

Your work looks absolutely great, and the fact its in a backyard makes it all the more impressive. Can't wait to see videos of the animal, or maybe it in the flesh.

Any shows you're hell bent on bringing this to?

H20i

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[quote="themagellan"]OB - A true inspiration.

Your work looks absolutely great, and the fact its in a backyard makes it all the more impressive. Can't wait to see videos of the animal, or maybe it in the flesh.

X2

You are as persistent as POP!

ringbearer wrote:

themagellan wrote:OB - A true inspiration.

Your work looks absolutely great, and the fact its in a backyard makes it all the more impressive. Can't wait to see videos of the animal, or maybe it in the flesh.

X2

You are as persistent as POP!

Thanks guys...
Things being added to the list as I wait for parts:

1) E85 Content Sensor (wiring)
2) Fuel Pressure Sensor (wiring)
3) Complete -8an PTFE Fuel Line from Filter to Stock UrS4 AAN Rail
4) Use the currently Unused UrS4 Oil Pressure switch (wiring)
5) Finalise the Meth Kit Wiring (wiring)
6) A double relay'd Launch Control circuitry that'll automatically activate it upon eBrake/Clutch/100% TPS input (wiring)
7) Re-pipe my windshield washer fluid lines
8) Clean Windshield washer Reservoir tank and Install a new pump in it
9) Ordered a Phenolic Intake Spacer
10) Possibly swapping in a 1.8t IAT sensor
11) Redline Synthetic Gearbox Fluid

Looks like I can tackle the hardware stuff first before the wiring... Lets see how the weekend goes...

Here's preliminary layout of the E85 Content Sensor setup....


Had to Modify some 034 parts to make it work, sigh...

Serious progress. Looking good. How much thickness does the honing take out of the cylinder walls?

Afterthought wrote:Serious progress. Looking good. How much thickness does the honing take out of the cylinder walls?

.0002 ... I used 220grit stone...

go go go go

Nice work my brother, cant wait to see her running strong.

themagellan wrote:go go go go

Yes Yes Yes.... Will I see you this year at any point?

ur.carlito wrote:Nice work my brother, cant wait to see her running strong.

Your Sig Pic looks sweet,... so ready for a FMIC install...

Let me know if you have some time next week, if you do, I'll assemble my LongBlock on the stand this weekend and we can throw it in in 1 sweep... Just waiting for the clutch kit...
If you're tied up, I'll probably just get impatient and do it piece by piece the we it was taken out... LMK

Would love to! I'd love to try to get down to h20, but at the very least let's get a little twisted somewhere local haha.

Hope to see some big progress this weekend (I just started the process to register mine and get it back out on the pavement!)

So the new kit has been in my possession but just now getting around grabbing some pics of it...

So what was my goal? Simple... Just a more reliable setup, with the same/similar capacity and pedal effort.

We (Marc & I) analyzed the current setup and the perceived "damage." We concluded it wasn't really as bad as we thought. Lots of oil in the PP and disc. It could've very well be cleaned up, revived and perform but we decided to just ditch the stock DMF and use my 7A SMF I had, for the sake of reliability.

[youtube]http://www.youtube.com/watch?v=isb43jG-SM0[/youtube]

What is IT?
Well it's basically a Stage 2 7A Clutch kit, but with the most aggressive disc pad available which happens to be a Dual Feramic Faced disc as in my previous setup. We shall call it Stage 2 Extreme!

As you can see, it's not a kit that built or listed this way on many vendor sites...




The existing kit












The New Kit...













Pressure plate comparison









Disc Comparison






Kit Comparison

quick, i want burnout vids!

chaloux wrote:quick, i want burnout vids!

Isn't that the proper break in procedure anyhow?

This is great OB, so excited it looks like this will be ready for h20 - On that note who and when are you going down with? I am really tempted to throw a wheel bearing in and make the trip to casa bonita hahaha!

What did you use to hone the cylinders? New Goetze rings? About to be doing the same...

amd is the best wrote:What did you use to hone the cylinders? New Goetze rings? About to be doing the same...

iirc - I think it was a drill, and one of these... but i'll let OB chime in.

http://www.amazon.com/Lisle-LIS23520-Gr ... B0002SREPO

There are just different abrasiveness hones and I'm not sure which is best for our backyard builds. lol.

amd is the best wrote:There are just different abrasiveness hones and I'm not sure which is best for our backyard builds. lol.

Yes... I used that 220 grit hone at the firmest setting... Only thing I don't like about that this style hone is that it only really works well in one direction... If I want to do a few passes in the counterclockwise direction long enough the inner shaft of the hone will unscrew and completely collapsed the apparatus. I like the fact that you can vary the firmness though.... Something the ball hone types don't offer as its more of a 1 size fits all since the come in 1-5" variants...

Another thing, these produce a lot of dust making you believe that you're removing a ton of material, when in fact it isn't... This I liked, as you never want to remove more than needed... Lots of WD40 and shop towels ect....

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Did you leave the crank in place and just pack the bottom end with towels to keep it clean?

amd is the best wrote:Did you leave the crank in place and just pack the bottom end with towels to keep it clean?

Precisely...... To further protect the crank surface/rod journal area, I connected the rod back ON the crank without the piston on, with the rods facing down towards the bottom not the block when I honed...

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