Straightupmad's Build (Updated 9/11/08)

[straightupmad]

Many of you may have seen my turbo build on the old site...

http://i260.photobucket.com/albums/ii24/straightupmad/Turbo%20Setup/DSCN1550S.jpg

http://i260.photobucket.com/albums/ii24/straightupmad/Turbo%20Setup/DSCN1339.jpg

http://i260.photobucket.com/albums/ii24/straightupmad/Turbo%20Setup/DSCN1549.jpg
(more pics are on my Photobucket site)

After more than a year of boosting, weak stock parts, one night of pushing too far, and possible bad gas, the car said enough last December...

http://i260.photobucket.com/albums/ii24/straightupmad/The%20Damage/100_0032.jpg

http://i260.photobucket.com/albums/ii24/straightupmad/The%20Damage/100_0037.jpg

http://i260.photobucket.com/albums/ii24/straightupmad/The%20Damage/100_0042.jpg
(again, more pics are on Photobucket)

Now, I will show my parts collection to fix the problem..

Ford Racing Oil Pump with CFM Billet Gears
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0224.jpg

Eagle Connecting Rods
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0223.jpg

JE Pistons with SwainTech's GoldCoat and PC-9 coatings
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0221.jpg

Focus-Power Billet Main Caps
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0067.jpg

Total Seal Gapless Top Ring Set and Clevite 77 H-series Bearings
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0212.jpg

PMAS Slot MAF
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0225.jpg

Graphite Exhaust Gasket
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0226.jpg

Crown Vic 4.6L SOHC Throttle Body
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0207.jpg

Jay Racing PCV and EGR Plates
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0222.jpg

There will be more parts added Monday...

[straightupmad]

I have also modified a few things to help performance or allow use of other parts...

Windage Tray clearanced for ARP Main Studs
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0063.jpg
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0202.jpg

Enlarge breathing port on valve cover
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0103.jpg
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0114.jpg
This is actually the first valve cover that ended up cracking due to trying plug the VCT hole with a freeze plug. My current valve cover has the threads positioned a little further to the top and is now powdercoated. Unfortunately, I don't have pictures of it as I have sent it off to have a custom spark plug cover made.

VCT Hole Plug
http://i260.photobucket.com/albums/ii24/straightupmad/VCT%20Delete/100_0123.jpg
http://i260.photobucket.com/albums/ii24/straightupmad/VCT%20Delete/100_0121.jpg

[straightupmad]

I am a little dissappointed as I was expecting my FRIM and cylinder head parts to arrive yesterday.....

Well nevermind, it appears that everything was delivered Saturday, but no one (FedEx or my apartment complex) decided to notify me. So, I will have to pick everything up tomorrow afternoon.

I will go ahead and update the thread with another part that I did not post earlier.

Ford GT Fuel Pump
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0126.jpg

Installed in the ZX2 basket
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0227.jpg

[ZX2WV]

jesus, i bet that fuel pump will work just fine. LOL.

looks good man.

[straightupmad]

looks good man.

Thanks.


More Parts...


Ford Racing Intake Manifold (Ver. 2)
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0228.jpg

Ford Racing "Stage 2" Valve Spring Kit & OEM Valves
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0229.jpg

I also got new valve seals and keepers, but there's really no need to post those. (No wow-factor. lol)

[ZX2 S/R Black]

Jebus!!!! this thing is gonna scream!!! looks good bro... keep updating

[zx2loon]

Awsome......question is now, how much in just parts??

[OGreaTFuzzY1]

yea i was wondering that also

~Fuzzy

[gt35r zx2]

looks good man

[straightupmad]

Awsome......question is now, how much in just parts??

to this point (including parts that aren't pictured) about $3800, or in other words, way too much.

[zx2reme]

Where did you get the pcv plate and egr blockoff plate from?

[straightupmad]

www.jayracing.com

[scortched]

to this point (including parts that aren't pictured) about $3800, or in other words, way too much.

in other words another zx2 lol. dude looks like you are going to have fun with it. i'll have to see it when it's done.

[raider]

how much hp does it make?

[straightupmad]

how much hp does it make?

everything is still in packaging/disassembled.

Update...
i just sent the head out to JohnP to have some work done.

i just got the crank, pistons, and rods back from getting balanced.

[ZX2R]

Way to do it right. :beer:

[straightupmad]

Update...

I got a few other things today...

Custom Spark Plug Cover
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0237.jpg

Torque Plate
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0238.jpg

I can, now, send the block off to get machined, so I can start putting everything together.

[zxtuner98]

Nice work. This is the way to do it. Wonderful work. Taking your time pay's off.

[zx2loon]

Holy shit.....lookin' good. Can't wait till it's all together.


BTW, you still owe me a ride.....I'll just wait till your finished to collect. :carrot:

[Blue ZX2]

Hm... so that torque plate is going to extend the block so you can do a huge stroker to it... Pretty insane! I cant wait to see this thing finished.

[straightupmad]

no, the torque plate is used during the cylinder boring and honing process. It simulates the cylinder head being torque to the block. Without it, the point loads from the head bolts/studs will bring the cylinder out of round, slightly, once the head is torqued down.

Loon, i am going to try to make it to your meet, so that you can collect. if not, we will have to work something else out.:wickywicky:

[Blue ZX2]

Ahh... still I was hoping for stroker like the add ons for the LS motors.

[vitaminease]

What kind of cams will you be running?

[straightupmad]

stock

[vitaminease]

Then why buy the Ford Racing "Stage 2" Valve Spring Kit?

[gt35r zx2]

for him to rev high , stock cams are great for turbo app., looks like a good build

[vitaminease]

How much did you pay for the FRIM, Valve Spring Kit, and where did you purchase them? If you don't mind me asking...

[scortched]

and where are you getting the block machined? somewhere local?

[straightupmad]

How much did you pay for the FRIM, Valve Spring Kit, and where did you purchase them? If you don't mind me asking...

$615 for the FRIM and $219 for the spring kit from Tousley Ford

and where are you getting the block machined? somewhere local?

Simons Balancing (off of Ashley River Road)

[Sir William]

Lookin good straightupmad!!

[ZX2 S/R Black]

I'm keeping both eyes on this build man! looks great! where you located?

[straightupmad]

Hanahan, SC (suburb of Charleston)

[scortched]

Represent the low country

[straightupmad]

I am still waiting to get everything back from the machine shop and JohnP is still working on my head.

I did get my Fidanza flywheel today, though...
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0240.jpg

[BlackEscortGT]

hey your progress is awesome. you can help me when i do mine...? I live in fort mill SC if you know where thats at?

[straightupmad]

hey your progress is awesome. you can help me when i do mine...? I live in fort mill SC if you know where thats at?

thanks. i'll be glad to provide whatever help i can. Fort Mill is kinda of a ways away, so I don't know if I could make too many trips to be there in person.

[BlackEscortGT]

o i know we should have a meet up when your done with anybody else in SC and Nc. are you going to loons meet?

[straightupmad]

Finally some progress...

Since the last update, I have also purchased a SPEC Stage 3+ clutch kit along with Ford bearings. I originally wanted to take Dubbs' advice and go with the ACT pressure plate. I still wanted to use a SPEC clutch disc, though, since they had discs that had higher torque holding capacities. After speaking with SPEC, they said their Stage 3+ and 5 pressure plates were proprietary/specialized/catered to the specific disc in these stages. If I wanted to use any other disc, I could use whatever PP i wanted. oh well.

Anyway, i got my block back from the machine shop...

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0324.jpg

Needless to say I have a lot of work ahead of me...

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0323.jpg

I started prepping the exterior of the block for paint and double checked the main bearing clearances.

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0328.jpg

Let's see how much I can get done this weekend. Also, JohnP says my head and IM should ship out Monday

[straightupmad]

I got the rod bearing clearances checked.

The piston rings are gapped...

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0331.jpg

I sandblasted the block...

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0332.jpg

I painted the block...

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0335.jpg

I coated the main bearings, rod bearings, wrist pins, and camshafts with a dry film lubricant.

Here is a pic of the internals...

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0334.jpg

[straightupmad]

I picked up some presents that the USPS said they had waiting for me on Thursday...

A PnP'ed head by JohnP

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0340.jpg

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0339.jpg

The combustion chambers are coated with a thermal barrier
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0341.jpg

Just to make it official...
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0337.jpg

After making sure everything was absolutely spotless, I started assembly with my engine cocktail (Clevite Assembly lube, Total Seal ring/piston lube, Total Seal dry film lube for cylinders, and ARP moly lube for everything with threads)

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0344.jpg

ARP studs and F-P main caps holding down the crank
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0342.jpg

The top side with the pistons sitting nicely in their new home
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0343.jpg

[straightupmad]

JohnP provided me with some very useful information regarding oil flow. The oil filter adapter/stud screws into the block too far and blocks part of the oil passage. The solution is to screw in the stud until the transition is flush. I locked the stud in place with medium strength thread locker. John also informed me of a way to improve oil flow by creating a channel in the block where the oil leaves the filter and enter the galleys.

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0346.jpg


I also took all the pressed in nipples in the FRIM out and threaded the holes for barb fittings
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0345.jpg

[Sir William]

Nice work bro. That channel is the exact info JohnP was telling me to do... I didn't quite know what he meant but now I do!!!

thanks

[zx2loon]

Your becomming my hero......:supernana:

[zx2loon]

Hey crackerjack!!

Why don't you give us an update?? :poke:

[99fordzx2]

^^^What he said.


-D

[ZX2guy19]

How much was it to get your block balanced and all that stuff? Also, how much were your billet main caps?

[inis]

I also took all the pressed in nipples in the FRIM out and threaded the holes for barb fittings
http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/100_0345.jpg


from experience (on my 2nd frim) , might wanna do something like I did.

http://kctuners.org/forum/uploads/1214023902/gallery_2_78_53990.jpg

[texas_04]

So are we going to get an update or not? Is this thing running or did it bloow up?

[zxtuner98]

Great Build! I enjoy reading it!!!

[straightupmad]

So are we going to get an update or not? Is this thing running or did it bloow up?

it's been running for a while now. i had a hard time getting the car to idle, and never did find out what was wrong in the tune. everything datalogged as fine. it also started to miss with any bit of load on the engine

i took it to a local dyno to start diagnosing problems. I tweaked the MAF transfer curve to give a little better A/F ratio, but the car still had a missing problem. judging by the erratic power curve it had to be an ignition problem.

wires were/aren't that old and checked fine. didn't see any problems with the plugs. i figured it was the accel coil finally going out on me. i haven't been able to find my stock coil for a while now, so i used this as an excuse to get an MSD coil. the missing problem persisted.

i finally moved some things around and scheduled an appointment with Tom from Focus-Power. we made the first few pulls so i could show him exactly what was going on. he agreed with the ignition being the problem with the missing. as Tom started to try a pair of focus wires (which would have eventually led to using a focus coil for the dyno tuning) i looked over the plugs real carefully. two had fine hairline cracks (found the ignition problem). swapped in a new set of plugs and finally things started turning around.

right as the car started to hit the 200hp mark the fuel injection fuse blew. we thought we had fried the computer. replaced the fuse and it blew as soon as we started the dyno pull. we ran a wire in replace of the fuse for the next run, and smoke started pouring out of the engine bay. apparently, the alternator/voltage regulator decided to fry itself and was sending a tremendous amount of voltage and current out. we replaced the alt. and previously blown fuse and all was good.

unfortunately, it was getting late in the day, and it was time to close up shop. with the car running (100 times better), tuning was stopped.

all said and done i left the day with a car that idled, a new alternator, and made 210hp (don't recall the torque). what's funny it that is exactly what i made on the stock engine. however, this is with the boost turned up slightly (lower compression lowers the engine's efficiency) and very fat A/F ratio and conservative timing.

recently, i made a change to the pcv plate, as it's design allows oil to be thrown into the vent line and taken out as crankcase pressure is relieved.
found this out at the dyno as well, as oil covered the entire length of the car from the 3.5 hr drive there and the multiple pulls.

http://i260.photobucket.com/albums/ii24/straightupmad/Rebuild/Image000.jpg

i have ordered a few misc. parts to redo the intercooler piping with mandrel bends.


i apologize for the lack of updates. i was waiting until i had all the kinks worked out and had the car in somewhat of a presentable setup. anyhow, this is where i am at now. i will keep working on it, improving it, and posting updates as things progress.

[straightupmad]

from experience (on my 2nd frim) , might wanna do something like I did.

thanks for the suggestion, but having the barb fittings coming straight out of the manifold work out great. the only place i could see that your way would clean things up is with the manifold reference for the fuel pressure sensor, but it doesn't bother me how i currently have it running.

[straightupmad]

How much was it to get your block balanced and all that stuff? Also, how much were your billet main caps?

the balance job was around $100. having the cylinders bored/honed, main journals bored/honed, bearing oil clearances set, etc. is a different story ($650)
the main caps were $360 with shipping.

[scortched]

Sounds good man i'd love to see it around christmas time when i come back to the low country

[koihoshi]

When this is done I wanna see a dyno! :)

[zx2loon]

I'm sure I'll be heading back down your way eventually to see Mac. When I do...you'll have to give me the ride you owe me from the last time we were at Mac's doing his suspension...:p

[Psychotuner]

free bump, Like to see finished pics, you guys are doing some good builds! Im curious about the oil passage channell and filter stud, elaborate more please.