Stu

Oh man, what a hectic few days! Finally have time to sit down and post a few photos. So I got in a couple of hours of tuning on Friday and managed to get the fuel map reasonably close to where I wanted it and ran up to 16psi. Definitely a whole different animal compared to the old T04e. Where the T04e used to deliver power kind of like "nothing nothing nothing then smashed in the face with a brick" the new turbo is much more progressive. In some places of the map I was adding in 8-10% more fuel so its definitely gobbling alot more air.

So I got it close enough and felt it was good enough to just run some gentle run for the Oldschool Drag Day on Sat. Loaded up the trailer and relaxed with a beer. Next morning the weather report was looking crap but my mate Joe and I decided to drive the 1.5hrs to the track anyway as Meremere has its own weird weather patterns and often is quite different to the areas around it. Glad we did as the track was clear and dry up until 2pm so got 12 or so runs in. Off the trailer and launching in 1st gear at 6psi needed a 13.1 which was right on the money where I was at last time. Was playing with the tune as I went in between each run and noticed that some areas the AFR's were 10.8 which is epic rich compared to where I wanted it to be so there is still room for improvement.

At one point I decided to add in 1 degree of timing to a couple of areas in the map and this made a staggering 5mph increase in trap speed. Ended up launching in 2nd gear and managed a new PB of 12.4 @ 113mph off a 2.09 60ft and pretty soggy 1/8th mile so very happy given the un-prepped track. I was keen to add a bit more boost and some more timing but the weather packed in so will try again at the Nationals at the end of January. Will definitely get some more boost into it and get the timing side of the table a bit closer to the mark. Thanks again to Joe and Kris for their help. Swapped cars with Kris for a few runs, he has a very cool KP with a very serious NA 4age setup. I somehow managed to be fastest on the day (it was and Oldschool day with everything from Morris Minors to VW combis etc) so scored a sweet trophy.

Here's some photos:

This is a mates extremely tidy KE20 with a 280kw 7agte setup. He was getting used to the setup and ran a string of mid 13's.

Beating on the poor KP

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I need to make a decision what I really want to achieve with the car. Will leave it as is and fettle a few things till the end of the season and hopefully get close to an 11sec pass, but after that who knows. Ive been wanting to build an ae86 for quite a few years so maybe just tidy the car up and enjoy it as is rather than pushing the envelope too much more. Will see how it all pans out over summer anyway.

Haha yep there isn't alot of space available! Weather report is looking average so Im not rating my chances. Might be a case of just cleaning up the tune for 6psi and wait for a dry spell to do a proper run.

Can you do something like I did? Modified the outlet so its 90 degrees to the front of the engine

Sorry this is the only photo I could find that shows it clearly.

https://youtu.be/nSph7TL1Chc

So time has been ticking so burnt some more late night hours to finish off the manifold and fabricate a downpipe bend from 3inch stainless due to a lack of space for an off the shelf bend. Not my best work but will do for now.

Which ended up a bit like this.

Slammed some heat paint on the manifold. You can't see due to the angle but the external provision is around the back and comes off the very bottom of the merge.

And the whole lot ended up looking like this.

Many hours later it was all fitted to the engine, oil feed and return were done, a stainless sieve from the supermarket was transformed into an intake cover for the turbo, intercooler pipe modified (will change this completely later on), external fitted and screamer pipe (for now) made up, alternator output wire beefed up, everything slammed together (see photo in the post above) with new oil and filter and it started right up.

Took it for a quick drive and on a gentle pull at 6psi and 70%throttle to about 6000rpm the afr's have leaned out from 12.5 with the old turbo to 13.3-13.4 so its a good sign the new turbo is swallowing a good amount more air. Didn't do too much else other than small cosmetic things but nice to be driving it again. Its been raining so I didn't bother road tuning it - fingers crossed I can do that tomorrow (Friday). Still need to dump the old fuel and swap it for the fresh stuff I picked up today. Fingers crossed it all comes together for Saturday.

Running out of time! 2 more days then its race time and still haven't started it up. No pressure

Looks great dude!

It may pay to narrow down what oil temp sensor you are going to use first, some of them are quite long and wont work in those links you showed.

I have used these http://www.nzefi.com/product/bosch-engine-oil-temperature-sensor/

and these http://www.nzefi.com/product/oil-temperature-sensor-with-right-angle-connector/

As requested

New manifold is done, very happy with how it turned out. Downpipe tonight then external wastegate merge. Its going to be a busy week! Hoping to get it running this weekend. The event I want to get to is the weekend after so no pressure...

Will do! Im back working on it tomorrow - its been a busy few days on the EP82 thats here currently.

Morgey, thanks! Its been a crazy year with being so busy on everyone else's cars, needed to make a start or get rid of the car.

5e colin, cheers dude. The old grinder merge seems to do the trick! Till I can afford to buy that CNC mill haha

Just got a new argon bottle so will get into it again this weekend, because no one likes it when this happens...

Physically yes, but you need to be running something other than factory engine management to tune them.

These EP91 boards were made by a guy here in NZ around 2004, i just happened to have a few of them left over and this is the last one. I had a small batch of EP82 ones made up years ago but most of my customers run full custom looms to take use of all the features of their ecu's rather than use the boards so I never bothered doing another run of them.

Yes I'd say you've caused the meltdown by powering it up by mistake unless something is trying to earth thru that circuit with a decent current draw causing it to burn out. Hard to tell really.

Sorry no idea about the relays, I havent ever wired a EP71 with a complete 4efte loom. I always strip the 4e or 5e engine loom back, remove all the chassis related wiring then merge that back into the factory EP70 engine loom. That way the factory EP71 fuse box and inside wiring stays the same and the engine loom becomes completely plug and play so its all nice and neat. Ive done 30+ of them now.

Good luck!

Ive got one of these if you need one, so you can wire any aftermarket ecu into a EP91.

The W pin supplies an EARTH to the check engine light in the dash cluster, there is no relay in the circuit. There is no feedback to the ecu so the engine will operate without it but you now wont be able to check for any diagnostic codes.

Dude that looks so good! That colour really makes it!

More un-adulterated grinding action (one handed for photo taking ability...)

Tacked together now. Ignore turbo outlet direction, the front cover is loose and its not pointing in the right direction in this photo.

Will knock it apart and to prep and weld up now, then work on the external wastegate provision.

With an aftermarket ecu you don't have to setup new triggering unless you want to, the standard pick ups in the distributor are fine, just remove the cap/rotor and add a blanking plate. K20 coils are a good option or 2zzge coils - there are two coil variants for the 2zz, both are the same except for one is slightly larger diameter and needs to be shaved down to slide down the spark tube. Have run these many times for customers with good results.

Link G4+ Atom would be perfect

Yes I would agree

Ah ok, well its possible they havent worked out the preload on the bearings properly? If the bearings don't have enough preload they can be quite noisy.

Yeah its certainly off putting when its making noise! Id go back to who built it and get them to take it for a drive. My guess is they havent set the preload on the diff bearings correctly and its a bit loose possibly. Did they pull the diff down as well?