Ivan280zt Posted November 15, 2009 Author Share Posted November 15, 2009 On with the good stuff Thats where the day ended. I might go by the shop tomorow and finish the downpipe and maybe even start on the intercooler piping. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted November 16, 2009 Author Share Posted November 16, 2009 Went back to the shop today and I spent few hours working on my downpipe. One day when I really need someone to give me hand with fitting and marking piping I get "stuck" alone well at least it was nice to have whole shop to myself. Since whole shop was full of cars I was not able to use any of the lifts so I had to use good ol jackstands method. This is how the day started. I just cant get enough of this view! Then I stared working on the downpipe Even though it looks like there is alot of space putting 4" pipe is not really that much fun I am not happy with end result so I am getting rid of the last 90deg bend. Then I am going to take about two inches of that 45deg bend and that is where v-band flange will be installed to seperate downpipe from the exhaust. There is just not enough space to tuck in 4" exhaust with v-band clamp under the car. Thats about it for this weekend I should be able to do some more work on it fallowing week during my lunch hour. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted November 20, 2009 Author Share Posted November 20, 2009 Yesterday was just another long day. I got home from shop around 11:30pm just freaking exhausted honestly I really cant wait to have my own garage so I can do this on my own time instead of doing it when I can barely stay awake. Ok enough of whining here are some pictures from last night. Some I/C piping action (we used aluminum 3" scrap piping because it pretty much cost me nothing). Passenger side starting point Saturday Drew is going to weld it all together and when that is done safety wire will be added to prevent pipes from coming loose. Since cold side piping is so short it would look very awkward to put Tial BOV on there so instead of that it will get mounted right on the I/C endtank under outlet pipe. More updates coming this weekend. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted November 22, 2009 Author Share Posted November 22, 2009 I am really not feeling like typing much tonight so here are some pictures of what was done today. Intercooler piping welded Turbo outlet all done and cooling down Tial Bov flange Welded together then drilled out and ported (no pictures of inside at the moment) Piping back in the car Notice lower intercooler brackets well they got redone too I was just not really happy with them so they got replaced with 1" square tubing Limited edition Tial green Bov : ) New intercooler brackets on the bottom From the front And one last shot for the night Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted November 24, 2009 Author Share Posted November 24, 2009 Now that intercooler is finalized I started working on my radiator setup. We had two spare radiator cores from our time attack EvoX so I tried test fitting it and what do you know its perfect fit : ). Now all I need is to bribe Cory (one of our train operators) to draw me some nice endtanks and we are all set. Guys meet Cory only thing you need to know about him is that he is just one badass dude It took him whole 10min to get done lol Core is two row which is more than enough for my setup Cory put order through today so endtank parts should be here in week or so. Well cant forget to pay the man Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 3, 2009 Author Share Posted December 3, 2009 Well I really enjoyed my visit to Alabama for the holidays and taking break from Z was even better : ). Last night I was really tired so I really didn't feel like sticking around for long and in turn not much was done lol. Here are few pictures of what was accomplished. Nice and comfortable in corner of the fab shop Drew building upper intercooler bracket I had to shorten downpipe by good amount so that massive v-band clamp would clear everything and this is final version. More updates coming this weekend. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 6, 2009 Author Share Posted December 6, 2009 Today was one of those days... just way to tired to get out of the bed let alone go to the shop and work on the Z but when you dont have your own garage and your personal project car is taking shop space well you dont have much choice no lazy weekends for me. Drew was nice enough to come in and give me hand with some welding so between two of us (neither one wanted to be here today lol) we got few small things done. Here is what we were working on. Drew welding on intercooler mounts Here you can see vibrant vaccum reservoir mounted on the bottom of the intake manifold Time has finally come to get downpipe welded and she came out awesome! Downpipe mounted on the car with wastegate pipe mocked up Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 6, 2009 Author Share Posted December 6, 2009 Then we started working on throttle body cable I had old lokar (I think) cable from my old L28 setup so we ended reusing it for new setup but few things had to be changed around. Pedal had to be bent 45deg to the right so that cable would not bind up against intake manifold (bad angle coming through firewall). Once everything is done all the holes on the firewall will get filled in and minimized including this one Take one hammer + Torch = no cutting and welding : ) Tabs for the linkage brackets Thats where was left off for today more updates coming later next week. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 13, 2009 Author Share Posted December 13, 2009 Wow long day at the shop yesterday. Between Drew, Chris, and me alot of custom fabrication got done and written of the list. Since it was the last day that I could keep my car at the shop (full of customers cars) I got there right about 9am by 6pm that night Z was done for the year and on its way to storage facility. Here are pictures of what we got done. Radiator end tank parts with -16an weld on fittings Drew putting radiator together Throttle body cable brackets Pedal needs little more work to line up perfect Then the motor came out (again lol) New transmission support Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 13, 2009 Author Share Posted December 13, 2009 Rivnuts installed for radiator mounts Radiator mounts tacked on ( 09 Gtr motor in the background) On the car with top mounts only Now I have to order radiator cap neck from summit and fab up overflow tank then Drew can weld it all together. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 13, 2009 Author Share Posted December 13, 2009 While Drew and me were bussy with our stuff Chris was rocking out with this awesome removable parachute setup. That bend in the bark looks like its off just little bit but it really isnt its perfectly centered our trunks curves are not symetrical as they might look. Chris machining down bar that slides through the body for better fitment More support from the side THE BLAIR WITCH PROJECT (yep we found their hiding place its in my damn trunk lol) Here is the best part everything can come out by talking out 4 allen head bolts! Done with the chassy for the year and she is off to the storage Now I can focus on some small parts for the engine and little random fabrication projects on the engine itself. I hope that you guys are enjoying fallowing my project as much as I am enjoying working on it. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 21, 2009 Author Share Posted December 21, 2009 Since holidays are around the corner I decided that I am done with Z for rest of the year. I could really use some time off and combined with few days off the work should do the job! Here is the last update for this year. New bolt for the oil filter housing that will be used for turbo oil feed (rethreaded for 1/8 npt) Old one New one So few weeks ago I asked Cory for draw me very simple plate for coil on plug setup. One thing with engineers is that there is no such thing as SIMPLE lol. His idea is to actually draw complete billet plate that replaces both factory covers with coils integrated into it. Cory is using our new portable CMM arm (coordinate measurement machine). Romer portable CMM allows him to digitally plot any given area he is working with. By taking the arm and touching key points on the valve cover he can digitally recreate the entire valve cover in CAD software. The end result is a product that fits like stock but with much better appearance. Corys starting with blank sheet Starting with four dots Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted December 21, 2009 Author Share Posted December 21, 2009 Almost finished just about time to start on coil on plug setup! All done for now Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted January 31, 2010 Author Share Posted January 31, 2010 Uhh update time I guess...lol I have spent most of my free time playing xbox live for like past month nothing better than relaxing in bed playing call of duty on 50inch flat screen : ). I did get to do few things but call me lazy I just dont feel like updating 100 pics so I will start off with few of external wastegate getting fitted on exhaust manifold. More coming up in fallowing weeks. Wastegate getting fitted from beginning to the end Trimmed for perfect fit Pretty much done All thats left now is to port runners some and to get head flange decked since she got warpped from runners being welded in one single night. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted February 1, 2010 Author Share Posted February 1, 2010 Next on the list are oil feed/return lines and here are some pictures of how that is going so far (quality of few pictures is not that good). Diry, used, and abused... lol I am going to upgrade rod bolts with some arp's before she gets put back together Factory casting for oil return which I belive is same as twin turbo motor but its just not drilled and tapped That can be fixed : ) -8 weld on fitting -8 oil return line with goodridge heat sleeve Before shrink tube Afther I am going to get bracket welded on turbo compressor outlet to keep line little more away from #1 runner just to be safe -4 fittings for oil feed (journal bearing gt42) One crazy Polish mechanic coming right up!!! My buddy Danny snuck in for this one lol. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted February 5, 2010 Author Share Posted February 5, 2010 Since 2jz seems to have alot of things that I wont be using I had Cory draw me few block off plates and we wanted to test them for fittment before order was sent out. Here are two of the "plates" getting fitted to verify clearance. Egr system There are few more but pictures came out really bad so I wont post those until real pieces came in. Next pictures are of the stock coolant inlet and outlet on the engine. Here you can see both of them and orientation of the lower one (which I ended flipping around thats coming up). -16 fittings welded on Insert your jokes here That nipple is not needed for anything so off it goes Back on the engine I flipped lower elbow 180deg so now it gives me better clearance and making lower radiator hose will be very simple. While ago I talked about adding another tab between throttle body brackets so that cable would not be hanging down its little things like that that really bother me so that will not be a problem. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted February 5, 2010 Author Share Posted February 5, 2010 Engine back in the car for final round of fabrication Header and wastegate fit great Downpipe really takes up alot of space and when dump tube is finished that space will be pretty much non existent. Last one for the night Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted February 7, 2010 Author Share Posted February 7, 2010 Today was one of those days...nah just kidding it was really awesome day! Made some great progress since there were three of us working on the Z at the same time! On with the pictures. I never got chance to show off what our awesome bead roller can do so here is how my piping looks like bead rolled Intercooler and piping back in the car Guess what goes there lol (nozzle is about 6-7" from throttle blade i belive) Since fuel rails for 2jzge engines are over $250 I decided that I will spend $20-30 and see how far I can take my stock one (or whats left of the stock rail lol) -10 feed and -8 return weld on fittings Fpr removed I wil get Cory to draw me block off plate with o-ring for it This is original fuel feed entry which I ended drilling out past -8 hole just trying to optimize what I got. I will use that port for fuel return. I ended cutting out end of the fuel rail and drilling it out to accept -10 fitting This fuel rail is so large on the outside that I had to problem drilling it through past opening of -10 hole so now I just need to get foot long drill bit and then I can drill through whole length of the fuel rail really making her support some serious fuel flow! -10 of the left -8 on the right For return line I am going with 180deg fitting to put me in right directionand to clear intake plenum including t/b cable (going with black fittings this one is just for test fitment) For feed line I am also going to use 180deg fitting with fuel line going right above fuel rail where fpr used to be. Drew welding Nos bung Iat bung Thats it for today more coming up over fallowing week. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted February 7, 2010 Author Share Posted February 7, 2010 Here are some more progress pictures as promised. Compressor housing off for welding of the turbo oil return line "support" bracket (to keep line away from #1 runner) Now I can just install clamp around line and that will keep it nice and safe from excessive heat Dump tube Almost there Support bracket for dump tube to prevent vibration and cracking since its made out of thin wall stainless steel Thats all mocked up now next step is welding that bad boy together. Quote Link to comment Share on other sites More sharing options...
Ivan280zt Posted February 9, 2010 Author Share Posted February 9, 2010 Since I am using thick wall ss with 1/2 header flange I am not worried about supporting turbo from the bottom but however side to side support from vibration and engine movement is whole another story. Here is nice and quick fix for that. Two unused studs coming out of the head just happen to be in perfect location for support bracket Just tacked together Once it gets welded it should turn out pretty nice with some amazing color change. Quote Link to comment Share on other sites More sharing options...
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