Quote from: Petrus on February  3, 2024, 20:52Wow      You have éarned feeling proud!!!

And thanks for sharing the tribulations.

Thanks @Petrus it is slowly getting there! One of the things I'm trying to do is make the kit transferable with as little modification to the actual car body as possible.

The only thing I've had to weld to the car do far are two exhaust hangers, but I'm not sure if this is slowing my progress. I just want to be able to lift it to another car if needed in the event of accident or sale really..

Bracketery didn't quite go as planned tonight. Came out a bit wonky, need to fix where the indent is and need to reduce the length of the studs further.. BUT it is offering some form of stability.

I need a big card board list of things to do like the pros do...

What's done:
 ○ fitted Stronger clutch
 ○ Route cooling hoses
 ○ Fit charge cooler radiator
 ○ designed built and fit exhaust
      
What's to do:
 ○ Put in new gearbox oil
 ○ Fit colder spark plugs
 ○ Buy and fit cone filter (possibly route to cooler place?)
 ○ Put jubilee clips on everything
 ○ Test charge pump and fill with coolant
 ○ Wire in charge cooler pump
 ○ Relocation of alarm
 ○ Change oil
 ○ Fit injectors
 ○ Fit oil lines for turbo
 ○ Drill sump and fit oil drain
 ○ Fit water lines for turbo
 ○ Place vacuum block
 ○ Fit boost solenoid
 ○ Fit boost controller
 ○ Fit Emanage
 ○ Combine standard o2 sensor wiring and fit narrow band
 ○ Fit Wideband sensor
 ○ Fit Wideband monitor
 ○ Finish fitting waste gate
 ○ Fit  oil catch can
 ○ change oil
 ○ check the hub nuts are done up
 ○ do up reasonably tightly all the rear suspension
 ○ get wheel alignment done
 ○ fit new power steering lines
 ○ Fit  new gear bearings
 ○ Fit  new gear stick (if it ever arrives)
 ○ Fit  new subframe (if it ever arrives)



Oooh boy I've got a while to go.
      
      
      

No mention of boost, oil pressure and afr gauges  in a nice, dash top pod? Bear in mind any that come with their own looms such as AEM will need extending and that's a whole lot of fun...

Quote from: Call the midlife! on February  4, 2024, 08:12No mention of boost, oil pressure and afr gauges  in a nice, dash top pod? Bear in mind any that come with their own looms such as AEM will need extending and that's a whole lot of fun...

  Cant believe you read through that list!
I've got an AEM wideband kit.. comes with a gauge and the boost controller is a greddy Profec job which has a digital display. But yeah, having run wires for oil temp and pressure previously it's not end of the world, it's just that there's minimal space under the passenger sill cover so might need to choose a different route..

Quote from: jvanzyl on February  4, 2024, 08:32 Cant believe you read through that list!
I've got an AEM wideband kit.. comes with a gauge and the boost controller is a greddy Profec job which has a digital display. But yeah, having run wires for oil temp and pressure previously it's not end of the world, it's just that there's minimal space under the passenger sill cover so might need to choose a different route.. 

The handbrake/gear cables run through a rubber grommet of sorts in the firewall, I put a hole in that and pulled a length of the convoluted, plastic wiring wrap through then fed all the gauge looms through that.
you can either unpin them or do a test fit with a length of random cable and decide where you want your join and pre cut them.
There's plenty of room inside the centre console for all the joins etc and you can run them under the shifter cage and up behind the stereo/HVAC panel.
if you're wanting them centre dash, in the cubby area you can drill through the bottom of the cubby but there's a big chunk of loom going across so be careful (I narrowly missed it so I'll be having a measure before going again on the 06 😂).

Quote from: Call the midlife! on February  4, 2024, 08:59The handbrake/gear cables run through a rubber grommet of sorts in the firewall, I put a hole in that and pulled a length of the convoluted, plastic wiring wrap through then fed all the gauge looms through that.
you can either unpin them or do a test fit with a length of random cable and decide where you want your join and pre cut them.
There's plenty of room inside the centre console for all the joins etc and you can run them under the shifter cage and up behind the stereo/HVAC panel.
if you're wanting them centre dash, in the cubby area you can drill through the bottom of the cubby but there's a big chunk of loom going across so be careful (I narrowly missed it so I'll be having a measure before going again on the 06 😂).

Thank you- I'll bear this route in mind. I'll need to quantify all of the cabling that needs to go through, see if I can use thinner gauges etc and then decide on which route. I do think I can save a fair bit of wiring etc just by having a common ground for most of them.

Quote from: jvanzyl on February  4, 2024, 13:54Thank you- I'll bear this route in mind. I'll need to quantify all of the cabling that needs to go through, see if I can use thinner gauges etc and then decide on which route. I do think I can save a fair bit of wiring etc just by having a common ground for most of them.

Double check the requirements for the emanange in terms of feeds from the gauges, I can't remember myself now how I did mine.

Quote from: Call the midlife! on February  4, 2024, 14:16Double check the requirements for the emanange in terms of feeds from the gauges, I can't remember myself now how I did mine.

Yeah this is going to be a learning curve.. I understand that it can take the Wideband input. The rest is whatever can be supplied to the standard ecu. Not amazing but hope that'll it work.

Updated the charge barrel bracket:



Then embarked on the next item:



Probably still don't have enough...



Discovered the difference between good and bad quality clips..



Aaand theoretically the charge system is ready for filling!

Mikalor hose clamps are a significantly better item than jubilee clips - fyi.

Quote from: Alex Knight on February  5, 2024, 14:21Mikalor hose clamps are a significantly better item than jubilee clips - fyi.

Interesting! Not heard of them before you mentioned but will definitely go them if the current batch don't work out.. only got 10 more clips to go on the pressurised intake now.

Quote from: jvanzyl on February  5, 2024, 13:49Aaand theoretically the charge system is ready for filling!

Lóve the instructions for the coolant 

Quote from: Petrus on February  5, 2024, 17:36Lóve the instructions for the coolant 

 

Today was a "pottering around" sort of day. I finished setting up the jubilee clips for the intake, and then turned my attention to the MAF housing as it turned out to have VERY unique screws holding it (the MAF) in place.. had to go through all of my pots of randoms to find things that would work!







That then brought me to the first dilemma.. the height of the MAF.. please see the following thread which I've created to a address this:
https://www.mr2roc.org/index.php?topic=74687.0

Then tried to fill the charge system to do a leak test and because the colour is very cool...






Buuuut then it all started coming straight out at me via this hole in the radiator!!


I have created another thread to try and figure out this one as well..
https://www.mr2roc.org/index.php?topic=74686.0

Rubber pipe, 2 jubilee clips and a bolt shoved in the end of it will do the job.
Easy way of bleeding it out too!

Quote from: mr2garageswindon on February  6, 2024, 15:03Rubber pipe, 2 jubilee clips and a bolt shoved in the end of it will do the job.
Easy way of bleeding it out too!

Ah thank you!  so you advocate closing it off and not connecting it to the coolant bottle? I have no idea what the right thing to do is- just don't want you create a point of failure!

It was meant to go to the bottom of the tank to allow for expansion, but it appears you've already allowed for that, so the bolt and jubilee clips method is good to go!

Entirely your personal choice but I used a different colour coolant for the charge cooler system, that way if you see a puddle you're already halfway to knowing which system is leaking...
As long as the two systems are fully independent.

Quote from: Carolyn on February  6, 2024, 16:45It was meant to go to the bottom of the tank to allow for expansion, but it appears you've already allowed for that, so the bolt and jubilee clips method is good to go!

Thanks for the reply to the other thread! I'm attempting to make this a bit more useful to other members by resolving technical difficulties in their respective areas vs on the reader's rude thread.

Quote from: Call the midlife! on February  6, 2024, 17:41Entirely your personal choice but I used a different colour coolant for the charge cooler system, that way if you see a puddle you're already halfway to knowing which system is leaking...
As long as the two systems are fully independent.

Now THIS is a good idea... wish I'd thought of this before ordering all the coolant.. oh well. But yeah they are completely separate systems.

I thought water was the best way forward? Instead of coolant.

Quote from: shnazzle on February  6, 2024, 23:23I thought water was the best way forward? Instead of coolant.

I just put a mild antifreeze solution in mine but then again I never actually got to use it before draining it down and taking it apart again.
It's all probably rusty and crusty by now 😂

Quote from: shnazzle on February  6, 2024, 23:23I thought water was the best way forward? Instead of coolant.

Water has séveral advantages for cooling over coolant fluids like glycol. The overall difference is surprisingly large. Do look into it if you are curious.
The system is however ámply designed for coolant use so with a minimally tuned engine the capacity is well sufficient.
If the system is to cope with significantly more heat, then water is the way forward with a difference if there is no risk of freezing. Else use the minimum %. of glycol.

On a side note; in years long gone by methanol was used as an antifreeze. and it does not have the cooling disadvantages of  glycol.

p.s. you can use a food colourant to change the colour of one system,

Thanks for the input folks!
I'll investigate some lurid colours for next time.

Bit of a milestone today as I managed to successfully bleed the charge coolant. And yes @mr2garageswindon  that rubber hose trick did provide a handy bleed point! Thank you!



In terms of the noise level it wasn't bad at all, and it got quieter after the bleed was done.



Video here as YouTube is demanding photo ID now to upload and I can't be bothered and the url posting in ibb doesn't seem to be working either.

https://gab.com/Cripkey123/posts/111890069901580437

Feeling the temp of the barrel with this thing going was good! Even with no forced air through the radiator I could feel the temp drop! Happy days.

Took out the old spark plugs:



And put the new colder ones in gapped to 1.1mm.





Great I thought - all buttoned up! What's next?
Injectors... aaah. Guess I'll be undoing a couple of buttons then..

Didn't get too far as I ran out of time. Was having slight nightmarish flashbacks of trying to get the fuel rail back in when doing the MAF mod all those years ago!





Tomorrow will be trying to complete this task and then trying to modify the aftermarket MAF housing so it's an exact replica of stock.