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Background: Driving home one day my timing belt snapped. Apparently it decided to walk itself off the back side of the cam gears and ground itself down against the belt cover. The engine had a slight rod knock so I have decided that instead of just fixing the head and having to potentially drop the engine because I spun a bearing I will just do a full rebuild now.
I have been planning on building this car since I bought it 3 years ago, but being a self sufficient college student I am low on funds for such a project. I have been researching this for about 3 years, but have no actual hands on experience with building car engines (I have rebuilt snowmobile engines).
Goal: 275-350whp , street driven (no drag), Daily driver
Here we go… Please post suggestions you have for me. This post is mostly for my benefit, but maybe others will find useful information here as well
Here she is:
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STEP ONE: Building the engine
Parts List:
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Does everything look in order here?
13 JANUARY 2012 UPDATE:
Alright, well it has been a long time since I wrote anything about my build mostly because I have been extremely busy with work and school that documenting a car build wasn't at the top of my priorities list. I do not have a garage to work in, and have been building this car outside in the cold winter. The car is sitting in my girlfriend's parent's driveway and has been since July. Its hasn't exactly been fun but it has been a great learning experience. I appreciate all of the help from Dino, Tim, Dave, Zac, and anyone else who has been in the chat to answer my questions and make fun of me.
Here are the pictures I have taken so far throughout this:
99RedGS Turbo Build
Here are some if you are too lazy to click the link and look at the album:
These pictures are all work in progress so clamps, wiring placement, etc are not finalized in these.
This is what I ended up going with, The only ebay parts are the Intercooler and piping. I tried to spare no expense on getting quality parts:
Bolt-on Modifications:
- s20g Turbo
- Hahn Turbo Manifold w/ 3" v-Band Downpipe
- 3" Exhaust
- HKS SSQV4 Blow off valve
- 2.5" Intercooler Piping
- 30x10X3 Godspeed FMIC
- Aeromotive 1:1 AFPR
- Walbro 255
- 550cc RC Injectors
- 4 AN SS fuel return
Engine Management:
- MS1 v2.2 3bar Map
- LC-1 Wideband
- 30/30 Autometer Boost Gauge
- Autometer Oil Pressure Gauge
Engine Internals:
- 10.5:1 Wiseco Pistons 88mm
- Eagle H-Beam Rods
- Clevite 77 360 degree oil groove main bearings
- Clevite 77 rod bearings
- 2.7L Rockers
- PT Cruiser Lifters
- Mechanical Timing Tensioner
- PS and AC Delete
- BKR7E Spark Plugs gapped @ .030
Drivetrain Modifications:
- Southbend OFE3 Clutch
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What all I have completed for the build thus far:
- Built and mounted engine in the car
- Completed all of the plumbing with SS lines ( Oil feed, Fuel Return, Oil drain)
- PS and AC delete
- Made a bracket and mounted the FMIC
- Cut intercooler piping to fitment
- Installed OFE3 clutch (provided by Zac) with new TOB
- 90% of wiring completed for MS system
- Gauges mounted and wired up
What I have left to do:
- Fill with coolant
- Wire up the power for the MS
- Wire up and mount the LC-1 wideband
- Fabricate a 3" resonator to connect the DP to the "cat-back"
- Bleed the clutch
- Burn a base map to the MS ( I am waiting on my serial to usb adapter to arrive)
- Have a welder apply a bead around the intercooler pipes that I cut so I get a better seal
- Plumb the vacuum tubing
- Mount AFPR (I accidently made my return line a little shorter than I wanted to I'm still problem solving this)
- Figure out a PCV system to prevent pressurization of the crankcase
- Install a new alternator
- Prime the oil pump before initial startup
- Rebuild the engine because I'll probably blow it up since I had no idea what I was doing on this build...
One problem I have is that the way the turbo is clocked the OEM cooling fan doesn't fit, and the A/C fan rubs the coupler. I'm still not sure what I'm going to do for this just yet. I don't want to buy a new radiator and fans, but I might not have a choice. Im thinking I might be able to fab up a bracket to mount the wastegate actuator so I can clock the turbo to a suitable angle.
I am hopefully a little less than 2 weeks from finishing this up (pending the weather). I am extremely worried about everything since I have so much time, money, and blood invested into this. I am so paranoid I am second guessing things like whether or not I put the HG on upside down or not. I will make a video and post it in the photobucket album if she runs when I try to start her. If all goes well and the build is solid she will be getting a fresh coat of paint, full new suspension (shocks, springs, all new arms), GSX brake upgrade, and a new windshield (cracked over the winter).
Please feel free to give me any info you think I need before starting this thing up. Ah Vtec... All of the lag with none of the turbo
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