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Feng Shui (The 510 Experiment) (Pics fixed through page 7..)


Josh K.

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Got the tranny tunnel done, just waiting for the rubber boots and flange to get here.

 

 

Started with this.

 

image.jpeg.ce138224e3a5f4f44aadd527bb5ed724.jpeg

 

Cut this out of a 240sx

 

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And made this.

 

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Looks like the motor is getting pulled to fix the floor, make new exhaust and rewire the whole car!

Edited by Josh K.
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Here's my favorite machine to program at work, she's my baby ;)

 

I made the MasterCam post processor myself.

 

Mori NL2500Y

 

2010-09-09113820.jpg

 

This was the first part I made on her...

 

IMG00036-20100629-1731.jpg

 

 

Dude,

Lovin the Mori. Must be nice.

 

Nice work on the dime. :cool:

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  • 3 weeks later...

Little update.

 

I wanted a better solution for the power steering delete problem. I decided I would use the Alternator Belt and make a new pulley instead of the junk yard scavenge/ possible misalignment solution...

 

I started with some ACETAL for the mock-up, final will be 6061.

 

Here's my progress, heading to the shop for final fitting before whipping a few out on the CNC Monday morning. This was done on a bridgeport manual lathe.

 

First I had to machine the inside bore to clear the pump.

 

 

image.jpeg.3ced3afeb8a160d6f654fe1b416cd48f.jpeg

 

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image.jpeg.2ca1fce486ba24f9a98f647106da7c7f.jpeg

 

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Then I created a Model:

 

 

image.png.6d23d5ffd55febd7410cf9adc976379f.png

 

image.png.f537d245a9e7eb5e8a7d6b62b5a8fa0a.png

 

image.png.92fa452f2c81ef13dc3af1c4d0b20b01.png

 

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Then I finished the OD and Pulley Groove:

 

 

image.jpeg.346483bb2ae691f5686e98d57bff6a8f.jpeg

 

image.jpeg.6fd59406563cc87778f8913554b38ba4.jpeg

 

I know the water neck will have to be modified, fitting to the motor and pics will follow....

Edited by Josh K.
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Today was throttle linkage day!

 

I didn't like the stock throttle linkage with all the springs and crap, plus I wanted to reroute the cable for cleanliness....

 

Next is grind off all uneeded bosses, weld up the holes and smooth the manifold. I'm also welding up the PVC tubes underneath the manifold. My plan is to make a plate where the PCV was, run a hose to a catch can and run another hose to a slash tube in the exhaust (like the honda guys...)

 

Here's part of the original linkage (I'm sure your all aware of what it looks like..)

 

 

image.jpeg.bddeedcccf271cd0e3ef921c4bb81667.jpeg

 

Here's my new linkage.

 

image.jpeg.58d323db18a8cd573b3bea2b3d5abde6.jpeg

 

I pulled the rod that the return spring hooks to, shortened it, returned the groove and pressed it back in the housing. Now the spring can't come off...

 

image.jpeg.51ed226da5a7ffa9840802f44ce4f17b.jpeg

 

image.jpeg.b943b95dfc6bcd83e7892ac721ddaeee.jpeg

 

 

Stay tuned....

Edited by Josh K.
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Hit list:

 

Grind all excess mounting points and material off intake manifold.

Hot tank manifold and weld up egr port and PCV ports.

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.

Contemplate machining a oil filter relocation plate....

Redo the whole Engine harness and relay/fues system.

Cutout the "hump" floor section and weld in new/old floor..

Weld in passenger seat mount.

Finish scraping the sound mat off the floors.

Weld up all holes in the floor.

Weld the new shift boot section from underneath the car and seal/paint

Seal/paint the floor inside the car.

Redo the whole exhaust system (possibly dual 2" with a crossover midway)

Possibly make a new transmission mount to reroute exhaust.

Finish modding gauge cluster to make aftermarket tach match white needle gauge set.

Slot rear crossmember and possibly cut second hole for dual 2" exhaust.

 

I'm also starting the planning stage for a supercharger. Been the turbo route before and feel like a supercharger would be the better option for my needs....

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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? :)

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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.... http://community.ratsun.net/public/style_emoticons/default/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!

 

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Edited by Josh K.
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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.

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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.

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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...).

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  • Josh K. changed the title to Feng Shui (The 510 Experiment) (Pics fixed through page 7..)

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