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Feng Shui (The 510 Experiment) (All pics are fixed)


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#41 Josh K.

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Posted 13 November 2010 - 07:53 PM

Hit list:

Grind all excess mounting points and material off intake manifold.
Hot tank manifold and weld up egr port and PCV ports. (Drop off tomorrow night, weld Tuesday)
Weld water neck where clearanced for alternator belt.
Machine a catch can for the PCV and weld a slash pipe in the exhaust to vent. (Start designing Monday)
Contemplate machining a oil filter relocation plate.... (Still contemplating...)
Redo the whole Engine harness and relay/fues system. (2 weeks out)
Cutout the "hump" floor section and weld in new/old floor.. (Next weekend)
Weld in passenger seat mount. (Next weekend)
Finish scraping the sound mat off the floors. (Next weekend)
Weld up all holes in the floor. (Next weekend)
Weld the new shift boot section from underneath the car and seal/paint (Next weekend)
Seal/paint the floor inside the car. (Whenever I can afford the supplies)
Redo the whole exhaust system (possibly dual 2" with a crossover midway) (Um.....)
Possibly make a new transmission mount to reroute exhaust. (Maybe?)
Finish modding gauge cluster to make aftermarket tach match white needle gauge set. (Next week)
Slot rear crossmember and possibly cut second hole for dual 2" exhaust. (When hell freezes over?)

Supercharger?

I need to sell my 12A-510 swap. Fund the supercharger? :)
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#42 Josh K.

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Posted 14 November 2010 - 01:15 PM

Working on the manifold today, got the upper all ground/welded/ground..... Gonna drop off both upper and lower to be hot tanked. After that I'll weld up the rest of the ports/holes and figure out if I want to polish/anodize/chem film? Chem film will make it gold.... smile.gif

My OCD is getting out of control......

I kinda like the rough cast look from the grinding bit?

Its hard to tell but I did A LOT of grinding on this thing. Almost the whole manifold was blended. Took about 4 hours!


2010-11-14124917.jpg

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2010-11-14124941.jpg
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#43 Icehouse

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Posted 14 November 2010 - 11:05 PM

Damn you do have OCD! Thats a lot of grinding. You should post some pics of your 12a 510!

"People don't like it when shit doesn't match their rule of thumb."    Sam


#44 Josh K.

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Posted 15 November 2010 - 07:38 AM

It's only a "swap", the rest of the car is my parts car now ;)

12A, 48MM Dellorto, Racing Beat Intake, stock top mount oil cooler, 510 front engine mount setup (Straddles the frame rails), 3 distributors, 2 coil sets, 3-5 speed trannys, 510 tranny mount and a 2dr 510 driveline for the 12A setup.
extras include a S5 turbo, 13B turbo manifold, 13B top mount inter cooler in case someone wants to go turbo .....

Looking to get $800 for everything. The Carb setup is$400, I'll throw everything else in for another $400 :) The motor ran good, carb worked perfect even with no choke and 20Deg weather! Setup is missing bolts here and there but overall its pretty complete. I'll post an add this weekend when I can drag all the stuff out for pics.
My 8? year KA24DET Powered 510 Engineering experiment.....

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#45 datsun510

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Posted 15 November 2010 - 08:05 AM

Josh,

Instead of modifing the water neck, just use the one off a 12V KA and it clears fine. Bolts on without a problem.

Seth

#46 Josh K.

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Posted 15 November 2010 - 08:10 AM

Josh,

Instead of modifing the water neck, just use the one off a 12V KA and it clears fine. Bolts on without a problem.

Seth


Thanks Seth,
I thought about that, I seen someone had clearance problems with the KA24E and the TPS Plug but it appears he had a dual plug TPS. We don't have a lot of junk yards over here so I decided to mod the one I had.

I'm going to move the Alternator to the driver side instead. This will give me more room for the supercharger. I'm swapping my buddy for his stock DE neck and he's gonna use the one I modified.
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#47 fisch

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Posted 16 November 2010 - 07:09 AM

So much win in this thread. Know there are a lot of eyes appreciating it! Keep it up!

#48 Josh K.

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Posted 16 November 2010 - 08:12 AM

Thanks Fisch!

Today I'm throwing my intake manifold on the CMM at work to get all the dimensions/profile for designing the Supercharger-Manifold interface. I think I'm going with the C230 M62. The Frontier/Xterra M62 that everyone uses is just ugly to me! Plus the C230 has an electric clutch if I want to utilize it?

First phase is get all the things on my list done and drive the car again... Once money allows I'll do phase 2 - supercharger. I'm moving forward with all the mods necessary to support the supercharger so when I'm ready it will be a painless transition. This includes relocating the IACV, AAC, Alternator, Oil filter and PCV Catch Can.

Soooo... This weekend is Alternator, Catch Can and Oil Filter (I'm avoiding the floor sheet metal work...).
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#49 Josh K.

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Posted 16 November 2010 - 01:03 PM

Preliminary Catch Can Design. The Perforated tube is the Inlet from the PCV Valve to separate the oil from the gases. The outlet will go to a tube in the exhaust to vent the Gases.

CATCH-CAN.png

CATCH-CAN2.png
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#50 Josh K.

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Posted 17 November 2010 - 08:21 AM

When did this turn into a build thread? I was just gonna fix the rear seat area......
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#51 Josh K.

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Posted 17 November 2010 - 06:45 PM

Todays progress report....

2010-11-17160641.jpg


I made a rookie mistake and cut the chamfers too deep... oh wait...I'm not a Machinist..... Fixed that later.

2010-11-17173845.jpg

2010-11-17182037.jpg
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#52 Icehouse

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Posted 18 November 2010 - 12:48 AM

That's the machine I like to run! Makes bad ass parts but isn't over the top. Machining is cool but takes way to long. I guess I'm inpatient in that respect. What did that part take, 3 hrs? Plus design time, which is totally worth it but when you pop the hood it's only dudes like us that know the time that goes into details like that. Looks awesome! Thats for sure.

"People don't like it when shit doesn't match their rule of thumb."    Sam


#53 Laecaon

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Posted 18 November 2010 - 04:27 AM

I want a mill so bad! There is one(10 or so, as well as 8 lathes and a CNC machine) at my school, but is only allowed to be used for school projects... <_<

Mills are fun to use though.

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#54 Josh K.

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Posted 18 November 2010 - 05:46 PM

Icehouse,
My feelings exactly... Why buy a $20 Catch Can from Amazon when you can spend 10Hrs. of your spare time making one? Because its EXACTLY the way I want it... smile.gif

And yes, 3hrs to make that part. Probably 1hr design time.

Here's today progress.

2010-11-18171605.jpg

2010-11-18172008.jpg
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#55 WAGON JON

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Posted 18 November 2010 - 06:20 PM

One little project at a time. This is a nice little tasty bit to make everyones mouths water. I love little bits like this. It makes your car personalized.
methylchloroisothiazolinone detective!
Encopresis breath!

#56 Josh K.

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Posted 18 November 2010 - 08:32 PM

Here's my Daily driver.

I replaced the motor, removed the emissions stuff and welded up the ports, new clutch, new weber progressive carb, rebuilt the battery tray and replaced the carrier bearing. She's really a champ!

2010-10-12171326.jpg
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#57 Josh K.

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Posted 20 November 2010 - 01:13 PM

Check the Catch Can off the list....

Grind all excess mounting points and material off intake manifold.
Hot tank manifold and weld up egr port and PCV ports. (Drop off tomorrow night, weld Tuesday)
Weld water neck where clearanced for alternator belt.
Machine a catch can for the PCV and weld a slash pipe in the exhaust to vent. (Start designing Monday)
Contemplate machining a oil filter relocation plate.... (It's now on the design list)
Redo the whole Engine harness and relay/fues system. (2 weeks out)
Cutout the "hump" floor section and weld in new/old floor.. (Next weekend)
Weld in passenger seat mount. (Next weekend)
Finish scraping the sound mat off the floors. (Next weekend)
Weld up all holes in the floor. (Next weekend)
Weld the new shift boot section from underneath the car and seal/paint (Next weekend)
Seal/paint the floor inside the car. (Whenever I can afford the supplies)
Redo the whole exhaust system (possibly dual 2" with a crossover midway) (Um.....)
Possibly make a new transmission mount to reroute exhaust. (Maybe?)
Finish modding gauge cluster to make aftermarket tach match white needle gauge set. (Next week)
Slot rear crossmember and possibly cut second hole for dual 2" exhaust. (When hell freezes over?)



Here she is! design changed a little on the shop floor...

I plan on stuffing the cavity with maybe a Brillo pad to help separate out the oil? Just gotta order the fittings from McMaster Carr

2010-11-20124318.jpg

2010-11-20124726.jpg

2010-11-20124735.jpg
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#58 Josh K.

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Posted 20 November 2010 - 01:18 PM

Here's the first pieces of my engine rewire! Gonna use 2 of these to go through the firewall to the ECU.

2010-11-20125616.jpg
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/

#59 jputz

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Posted 20 November 2010 - 08:54 PM

wow man love the catch can it looks amazing. Wish I had access to the machinery that you guys do. Custom parts are the shit. Anyways great build good luck with your list!!

#60 Josh K.

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Posted 20 November 2010 - 09:09 PM

Thanks!

It's nice to have keys to the shop on the weekend! As long as a machine doesn't have a job setup then I can do what I please ;)
My 8? year KA24DET Powered 510 Engineering experiment.....

http://community.rat...98-the-phoenix/