Sir William's turbo rebuild Updated July 16th

[Sir William]

As many of you know, the ZX2 has been off the road for some time.

I'm in the process of redoing the worklog so I'll be adding to this as the next few days pass.

I'll start out by showing the Car and engine bay before the project began.

http://img386.imageshack.us/img386/1651/1000359go6.jpg

http://img113.imageshack.us/img113/449/0000276lo0.jpg

The reason the project grew into something more than just an engine rebuild is the fact that Crys and I purchased a garage and the owners threw in a house.

Pic of the workspace from the previous owner
http://img300.imageshack.us/img300/7590/2346691sc2.jpg

Here is the engine that I picked up for the engine build
http://img386.imageshack.us/img386/8792/1000406jp0.jpg

After tearing it down...

Before some smart A** says something about parts being laid out on a 57 chev..... my buddy who owns the car put them there... it's our next project a full fram off restoration.

http://img66.imageshack.us/img66/1152/1000425xm6.jpg
http://img338.imageshack.us/img338/5548/1000442yo4.jpg

Me hard at work
http://img505.imageshack.us/img505/1496/1000586ri7.jpg

Block put back together after slight overbore and balancing.
Crower rods and JE pistons 9:1 CR

http://img386.imageshack.us/img386/4452/1000602wn4.jpg
http://img372.imageshack.us/img372/5124/1000601ry7.jpg

I decided that the old turbo setup needed to be changed... I just didn't like the way it looked and had too many issues with the manifold cracking.

Pic of the old manifold

http://img115.imageshack.us/img115/2403/1000651xp5.jpg

Pics of the new manifold and downpipe

http://img104.imageshack.us/img104/4610/1001115ue1.jpg

http://img386.imageshack.us/img386/8228/1001121yy3.jpg

http://img505.imageshack.us/img505/1663/1001120mk0.jpg


The other reason that I decided to make this a full project doing the engine, exterior and interior is that I picked up a donor car from a member.

Several of the parts have come from the donor car, are new parts, or are parts purchased from TZX2 members.

Seats and interior are coming from the donor car

http://img151.imageshack.us/img151/8396/1001022gu7.jpg

Misc shots of parts laying around the garage now

http://img150.imageshack.us/img150/716/1001019nx5.jpg

http://img151.imageshack.us/img151/2103/1001018yh8.jpg

Valve cover coated by Skuce

http://img395.imageshack.us/img395/7689/dsc00332do0.jpg

New rotors I just got in the mail (since the rear disk swap)

http://img158.imageshack.us/img158/4222/1001160br2.jpg

The baby I waited a year for

http://img374.imageshack.us/img374/2523/frim1ns9.jpg

The modified mustang TB being used with the FRIM

http://img204.imageshack.us/img204/8374/1001110ji6.jpg

New front bumper with WW lip (not the color I'm going with) and I picked up the sides and rear in may so I now have a full WW kit for the car

http://img338.imageshack.us/img338/8180/1000527jd5.jpg

Some of the other goodies

http://img263.imageshack.us/img263/8816/1001157lb8.jpg

I couldn't pass up the deal on this so I bought it too

http://img48.imageshack.us/img48/3403/1001155ev4.jpg

not pictured is a set of Mazdaracer's lower tie bars.

a quick snapshot of the front end with the suspension almost done (minus new rotors)

http://img395.imageshack.us/img395/3955/1001159rp7.jpg

Engine bay.... something is missing.... lol
actually took the pic to show the manual rack installed.

also I have ES all the way around on this car

http://img66.imageshack.us/img66/497/1001158bp9.jpg

That's enough for now.... I have to get ready for work..... I'll post more in the next few days.

[powder]

Nice dude!

[CraZx2ing]

Great work man. Looks like a lot of fun!

[pure]

I can't wait to see this beast together!

[WillZX2]

:hitnana::ttnana::hitnana: come to Ottawa and do mine next

[zxtwou2]

lookin awesome, D!!!

[Sir William]

I know there isn't any chronological order to this thread.

There will be from now on.... I just had to redo it all so I kinda threw it all together. But here we go.

Here is a pic of the suspension together with the SS brake lines, painted calipers and the coil overs on.... Now I have to take some of it apart again to install the lower tie bar for the front.

http://img395.imageshack.us/img395/3955/1001159rp7.jpg

pic of the rear disk conversion with the painted calipers.... yeah it'll look a ton better with those new rotors.

http://img408.imageshack.us/img408/9360/1001063di8.jpg

Pic of the manual rack next to the power steering rack

http://img104.imageshack.us/img104/9730/1001057en5.jpg

I coated the whole underside of the vehicle with truck bed liner (here is the rear cross member)

http://img66.imageshack.us/img66/6973/1001015vt8.jpg

Look ma, no Ford symbol!!!

http://img402.imageshack.us/img402/9392/1000530fl4.jpg

OH!! Found another shot of the 57 with my parts on it

http://img385.imageshack.us/img385/2193/1000411xx1.jpg

Random pic that has nothing to do with the build.... well she is the woman that is putting up with this project so I think she deserves some recognition.

P.S. she hates this pic and would kill me if she knew I posted it. lol

http://img129.imageshack.us/img129/5931/1000246rt5.jpg

That's it for now...

I left out a bunch of the pictures from the actual build... I figured I wouldn't bore you all with pics of me tearing down the motor.. or installing rings on the pistons.

Much more to come.

[TTFOWIA]

^^ pics not working :P

[Sir William]

^^ pics fixed

[5Speed]

Looks Good Buddy, That's Skuces old front end isn't it? 4 Door ZX2? Paint sure looks like it.

[slammmed]

looks like afun build. good luck with everything.

[Fat_Dave]

wire tuck FTW!!!

[Sir William]

Looks Good Buddy, That's Skuces old front end isn't it? 4 Door ZX2? Paint sure looks like it.

Why yes it is!! Skuce and I live pretty close to each other and he's been a huge help with contacts and information.

[Sir William]

wire tuck FTW!!!

That is a serious contemplation for a winter project... the main issue right now is getting it back out for Cappy's meet.

[ZX2guy19]

Lookin' fresh man.

Out of curiosity, what are you doing with the trans?

[Sir William]

For now just putting in a MSP LSD.

Once I blow up 3rd gear I'll be doing something different

[TTFOWIA]

same here ^^

[Sir William]

Sorry about the poor quality of the images,

I ripped apart 2 transmissions on the weekend so that I could keep the guts of the one and put the LSD in the other.

http://img238.imageshack.us/img238/9407/p00060oa4.jpghttp://img123.imageshack.us/img123/6951/p00061dl7.jpghttp://img48.imageshack.us/img48/9021/p00062pc4.jpg
http://img106.imageshack.us/img106/5796/p00063cl4.jpghttp://img48.imageshack.us/img48/8307/p00064rz6.jpghttp://img110.imageshack.us/img110/300/p00066yl7.jpg
http://img119.imageshack.us/img119/2953/p00067tx6.jpghttp://img50.imageshack.us/img50/9731/p00068ub2.jpghttp://img161.imageshack.us/img161/4698/p00069xy3.jpg
http://img102.imageshack.us/img102/1200/p00070hv6.jpghttp://img518.imageshack.us/img518/9730/p00071gz1.jpghttp://img239.imageshack.us/img239/2913/p00072wt1.jpg
http://img108.imageshack.us/img108/6385/p00073uv1.jpghttp://img125.imageshack.us/img125/2272/p00074dw0.jpghttp://img162.imageshack.us/img162/7720/p00075rm7.jpg
http://img240.imageshack.us/img240/6143/p00076xv1.jpghttp://img119.imageshack.us/img119/3312/p00077nr9.jpg


I didn't take any pics beyond here cause it's pretty straight forward and I didn't need any reference pictures for myself.
Now for the install of the LSD and to put the thing back together

[5Speed]

Wanna give me your spare tranny hahaha!! Good work Darryl.

[Thnikkaman]

nice work! lol canadian tire jack stands! the very same set hold up may car!

[WillZX2]

nice work! lol canadian tire jack stands! the very same set hold up may car!

me too actualyy lol

[Sir William]

Canadian tire 50% off or more FTMFW!!!

All my tools come either from there or Sears

[TTFOWIA]

^^ x2. except for the Sears part... :P

[gunman_sr5]

Lookin good so far

[Thnikkaman]

most of my hand tools are Craftsman but pretty much everything else is canadian tire... or powerfist! lol princess auto FTW! you cant beat princess auto for that tool you only use once - super cheap, but if you use it more than once its probably going to break.

[1981gMachine]

Subscribed

[99fordzx2]

Whats that blue thing in the back right of the engine bay in the first pic? And whats it used for?


-D

[Sir William]

That would be a vacuum manifold. It's used to take 1 source of vacuum and make it 4 (in the case of this one).

I am guessing you mean the anodized blue rectangular thing to the right of the brake fluid resivoir.

[Sir William]

Here are some updated pictures from the work being done....

far from finished though. The last pic is my tranny with the MSP LSD installed and put together.

http://img518.imageshack.us/img518/7826/1001173rz0.jpg

http://img72.imageshack.us/img72/5595/1001172ao0.jpg

http://img339.imageshack.us/img339/5766/1001174uo8.jpg

http://img124.imageshack.us/img124/6450/1001175sz9.jpg

http://img72.imageshack.us/img72/9529/1001176xi2.jpg

http://img235.imageshack.us/img235/9501/1001177xo9.jpg

http://img205.imageshack.us/img205/9845/1001178am5.jpg

http://img339.imageshack.us/img339/6443/1001179nm1.jpg

http://img296.imageshack.us/img296/7324/1001180ms8.jpg

http://img296.imageshack.us/img296/521/1001181hl7.jpg

http://img174.imageshack.us/img174/2597/1001182qt5.jpg

http://img518.imageshack.us/img518/3302/1001183jj4.jpg

http://img124.imageshack.us/img124/7306/1001184ek4.jpg

http://img339.imageshack.us/img339/8995/1001185mq0.jpg

http://img72.imageshack.us/img72/1387/1001186dp3.jpg

http://img235.imageshack.us/img235/8896/1001171pi3.jpg

http://img296.imageshack.us/img296/12/1001187hi1.jpg

[powder]

Nice dude. What's your time frame on gettin her runnin?

[Sir William]

I hope a week or two..... but it could take a bit longer

[krux]

it'll be running tommmrow

[TTFOWIA]

sweeet... can't wait to take pics of mine like that next week... any news from Rob? I didn't get any... really pissed now... the car is gonna be ready to roll except for those damn axles in less than 5 days so... (same for u I guess :P)

[Sir William]

Well, I did a bit more work on the engine today...

Things are coming along nicely. I hope to have it in the car next week sometime.

here are some updated pics.

http://img375.imageshack.us/img375/6711/1001200mm7.jpg
http://img75.imageshack.us/img75/4553/1001199bi2.jpg
http://img379.imageshack.us/img379/5101/1001198va3.jpg
http://img93.imageshack.us/img93/7357/1001201hr3.jpg

[krux]

pssh stop posting pic's of my engine ;)

[corby_baby]

zomglyk3makemione

[TTFOWIA]

looking GREAT :D

[ZX2guy19]

Stop. It looks too good.

[MrWeeyums]

Wow that looks sexy.
~Ryan

[Waterboy9000]

Hey if you decide you wanna part with it, id take that front bumper/ww off your hands

[zxtwou2]

want the ultimate test of how good she'll run? drive it down to see me :D

[capitalcrew]

Well, gonna make it? :D

[Sir William]

Well, gonna make it? :D


not lookin good... I still don't have the axles.. and there are other things that need to be done.. tune, exhaust, alignment, turbo pipes... stuff like that... small but takes time

[Sir William]

want the ultimate test of how good she'll run? drive it down to see me :D


You never know ;)

[capitalcrew]

Bah! Put it together without the turbo stuff and just drive here n/a. haha

[Sir William]

okies....

I had a fight with the rear tranny mount today... but I finally got it in.

http://img516.imageshack.us/img516/5486/1001354ix6.jpg

http://img183.imageshack.us/img183/8860/1001353vx8.jpg

http://img178.imageshack.us/img178/2262/1001352cw1.jpg

I tried something with the rad supports... IDK if I like it or if I'm going to use it though....

http://img112.imageshack.us/img112/5194/1001355ol2.jpg

[capitalcrew]

Nuhice. I want to see this thing runnnnn.

[krux]

good job bro..im a uber jealous

[MrWeeyums]

It looks so happy to be in its home.
~Ryan

[5Speed]

i like the rad brackets... keep up the good work bro.

[JohnP]

I've been watching , nice clean job , everything looks excellent . Won't be long before you fire it up , it should make some good numbers .

[powder]

Nice dude!

[ZX2 Sleeper]

The engine doesn't look good in your engine bay. GIVE IT TO ME! :)

[gunman_sr5]

Its to pretty.

[2000zx2chik]

Looks super good!

[decay]

Nice work, bro!
BTW - Took a new job in Scarberia. Will be back in the Oakville area so get that thing done and drive it to work! I will surely be passing by the Ford plant in the coming months....

[ChillinZX]

Where did you get the lower tie bars from?

[powder]

Mazda Racer.

[99fordzx2]

What turbo manifold is that?


-D

[krux]

fire the car up. you know you love rob at zxtuner

[gunman_sr5]

Whats the latest update?

[Sir William]

Still waiting on axles from Rob..... what's it now... 6 months???

[TTFOWIA]

hopefully it's not gonna be the same as mine... too short.

[ZX2guy19]

Are you guys fucking kidding me? Fuck that man, I'd be flying my happy ass out to pay him a visit. I've never heard of such a thing.

[TTFOWIA]

worst thing with me is that I never been able to recontact him to get the 300$ it cost me to have it fixed locally.

[ZX2guy19]

Thank god I got mine used for $200. Dude that is so ridiculous. PM about to be sent.

[ZX2Fast]

Now you guys know why I was trying so hard to find a stub shaft so we could use our factory axles.

[TTFOWIA]

pm replied :P

[Sir William]

Update... still waiting on Rob... time to take some other action.

[ZX2guy19]

no fucking way...

Dude, fuck that.

[Sir William]

Yeah, I left a rather blunt message for Rob, and said I'd be contacting the DA's office if he doesn't reply in 48 hours.

[ZX2 Sleeper]

i saw your away message on aim! Lol at that.

[corby_baby]

please tell him to stop being such a dbag and run a business the right way.

[TTFOWIA]

I'll be pickin up my axles tomorrow, I'll let you know if you want some just tell me.

[ilarson007]

nice car... but i agree... the engine doesn't belong in your car... you should just give it to me ;).