Been a while... update time

[DaFlyinSkwirl]

been a LONG time since I lurked here, but figured I'd stop by for a visit and update you guys on what I've been up to..

2.0 ecotec bottom end (LSJ) and 2.2 ecotec head (L61) hybrid.

initially planned on staying all motor, but decided to go with a large turbo instead. my goal is 450hp at the wheels (roughly 500bhp?) with a stock engine.

what started out as a small experiment turned into a long term project, 1.5years and counting so far..

say hello to DaFlyinSkwirl v2.0

april 13 2008.. it begins.

LSJ block with ARP headstuds, ready for assembly.

eliminated balance shafts, adjustable cam gears, 2.2 head

test fitting the turbo manifold. log style for now with external 38mm wastegate

F23 transmission mated to the LSJ (2.0) block. oil cooler was a tight fit, and I had to work around it for the lower rad hose

satin black paint under the hood

new look before hood pins

aerocatch hood pins installed

mocking up the fuel cell

fuel cell finished (ignore the crap welds.. its solid!)

mock up of the 3" charge pipe

overhead shot

HVAC removed, insulation removed, dash cage painted and reinstalled

left over wiring..

what remains

fabricated HVAC blockoff plate

fuel cell, pump, return, vent lines all hooked up

adjustable fuel pressure regulator

fuel lines to the tapped rail

modified brake pedal arm and master cylinder extension (before being cleaned up and painted)

welded fittings on thermostat housing

relocated coolant expansion tank and added recovery tank

new master cylinder (brake booster and ABS EBCM eliminated)

new brake layout compared to stock.

stock boss and rksport mount in jig

my custom mount in jig

test fit

final product

comparison to stock boss/rksport mount

solid transmission bushings

i've also made a solid lower dogbone.

the brakes are bled and working. I have all new wheel bearings/hubs, EBC rotors and pads up front, and OEM replacement rear drum brakes with all new hardware shoes and drums.

new driveshafts are enroute, clutch master cylinder, tubing for me to fabricate the next exhaust system. Car is almost ready to be placed on the ground.

I still need to finish the cooling, vacuum and electrical systems. I then have to do the interior with fixed back racing seats, 5 pt harnesses, and all new gauges. Carpeting and interior panels will be going back in place as per my class rules (stock appearing interior)

following systems have been completely removed (all wiring associated with as well)

ECM
BCM
HVAC
ABS/ EBCM
Brake vacuum booster
SRS system (airbags)
Radio
EVAP
Coolant expansion tank relocated


custom fabricated things:

expansion/recovery tank brackets
solid one piece upper motor mount
solid lower dogbone motor mount
solid transmission bushings
-AN fittings on thermostat housing
-AN tapped block mount oil-to-water oil cooler
-AN tapped fuel rail
coil mounting bracket
battery tray drilled out and custom mounted battery
rear spare tire well removed, fuel cell bracket welded in
custom fuel pump mount

the car is being built with drag racing in mind, driven only once in a while on the street.

3" exhaust with side exit behind driver door. 3" charge pipes, and either a very large air to air intercooler in the front bumper, or I'm going to try going with an air to water unit.

 

[Drakey]

WOW.... That's a lot of time and effort gone in to that, you've certainly been busy. Thanks for updating us on your progress, going to be one hell of a beast once finished.

 

[blue se2]

Nice work you have been very busy keep the pics coming very interesting read this!!

 

[vocky]

I check your build thread on J-Body every week, but this thread is far far better :clap: :clap:

I'm very impressed with your build, can't wait to see it finished, love the pics of the turbo pipework - I haven't seen them before

 

[Sjdickso]

Nice project thread, Some great work.

 

[Matt]

As said, great project thread. Looking forward to seeing some more

 

[EcotecFiero]

I agree no 8 pages of crap to dig through for the good stuff!

 

[DaFlyinSkwirl]

been busy...

ordered corbeau forza seats in black cloth, silver 5 point harnesses with cam lock release, and double locking sliders.
also ordered the remainder of the cooling and vacuum lines so hopefully i'll be able to wrap those up finally.

started looking into making a custom harness bar, or doing a bolt-in temporary 6 point cage install

I also managed to finish the test phase exhaust...

the whole system is 3", and all v-band connections. collector on the 4-1 header is also 3", so the system has no taper, and other than the 45* bend on the downpipe, no turns either.

managed to finish my carbon fiber STi gauge pod retrofit...

its not show quality, but it looks decent enough and will get the job done. I no longer have an HVAC unit, so the vent that I'm covering now is no longer needed. a little quieter than an a-pillar pod IMO.

I modified the dash so the pod sits inside, and bolts through a stock hole that held down the vent cover. Other than the tiny gaps on the sides which can't be helped, it looks pretty damn good.

I also started working on the electrical and remembered why I decided to put it off until last.

 

[Mark Dj]

Looking good, alot of hard work has gone into this. Well done

 

[sdbutler10]

Wow what a build. Keep it updated looks amazing mate. :-D

 

[vocky]

you have been very busy :clap:

the electrics aren't that hard, just take your time

 

[JohnnyN]

Bloody outstanding craftmanship there! Well done!

 

[DaFlyinSkwirl]

thanks a lot for the compliments guys! its that kind of stuff that lets me know I'm still on the right track, and gives me the drive to keep going. cheers..

its been a long road thus far, and I can definitely see the light at the end of this long tunnel. It won't be turbo for a few months while I test all the systems and make sure they work right, but once those tests are passed, the car goes back into the garage for the turbo setup.

then the REAL fun begins :twisted: