Turbo Goose Posted January 15, 2015 Author Share Posted January 15, 2015 Good evening people. Thought I would update this as I haven't in a while. Got about a million pics so will just share a few So I got the car running sweet on a TF035, was spot on everytime I went out in it. One day I was giving it some sugar past a row of cars and felt a judder and a splutter so backed off after I realised my engine management light had come on. Coasted home about 40mph and parked up. Following day I checked a few things over, changed the knock sensor as this was the code flagged up by engine management, Took it for a spin and it was very sluggish. Found my vac pipe had popped off the wastegate Bought myself a compression tester, turned out I had 0-40-50-45 psi across the 4 cylinder, Oh dear...... Anyway, expected the worst so started to take engine out.Long story short, got the engine out, stripped it and I had bent 2 rods add smashed a piston, That's what 2.8bar does to a standard engine! Banana rods My first thought was to rebuild a standard engine, much cheaper and the sensible option. Then I was 99% sure I would want more power in the future as I had already maxed out the standard engine at 229bhpThe only option really was a forged lump. Looked into buying a used one but thought if I do it myself I know its done right. Although looking back its nearly cost me 1.8k at this point and you can get them built for 2k at either racetech or TD. So gathered a load of bits. Wiseco 74.5mm pistonsScat rodsKing bearings1.2mm headgasketARP headboltsRX8 430cc injectorsFull gasket setToyota oil pumpBlueprint waterpumpTiming belt kitSard FPROil pressure gaugeInnovate widebandAN8 bits and bobs for rockerSamco rad hosesD1 spec wheel nutsPolybush engine mountsOptional rear strut with pasticsUltra racing RARBTRD shocks and springsCelica ST185 brake setupD1 reservoir socksCusco battery clamp And many other parts I cant remember Customs spanked my ass for the rods and pistons!! Glanza looking sorry for itself Car FULL of parts Gave the engine bay a shimmy Been doing a few bits at work, theres many welders, shot blasters, heat treaters, degreasers, polishers etc etc so its quite a useful place to work Smoothed inlet manifold, welded on some an8 fitting to rocker cover and got it shot blasted Sprayed my rocker cover Polished some bits at work Build a fresh TD04 Welded the screamer into the downpipe. I prefer the sound of my 5zigen over a screamer pipe any day (pic if of it before it was welded obvs but you get the jist) Cleaned my head in our mammoth degreaser! Managed to find an engine builder local to me who is a proper sound guy. He builds drag bikes for a living and was recommended to me by a few people.Work I had done there was crank polish, rebore, block notch, steam seals, valves seated and cleaned, head skimmed and blocked top cleaned, rings gapped. That's what stage I am atm. Future plans are to paint the block and head, Put engine back together, clean the gearbox and fit. Need to finish installing the wideband, oil pressure gauge and boost gauge Once its all back together I will be running it in on standard injectors and TF035.After run in period I will be fitting 430cc injectors and the fresh TD04 and taking it to racetech for a remap! Happy days.... Quote Link to post Share on other sites
Charlie28 Posted January 15, 2015 Share Posted January 15, 2015 Looking good mate! Making good progress! What engine management you planning to use? Quote Link to post Share on other sites
Ollieh17 Posted January 15, 2015 Share Posted January 15, 2015 Polished stuff looks awesome mate, kinda wish i went for polished bits on mine! Quote Link to post Share on other sites
Turbo Goose Posted January 15, 2015 Author Share Posted January 15, 2015 I have an emanage blue. Posted a thread up about it whether or not i should go ultimate or not but most said for under 300 bhp the blue will be fine.Ye ollie, i didnt even realise they did polishin at my place so i chucked the lads them bits to see what they could do and my jaw dropped when i saw what they could do! Quote Link to post Share on other sites
Calum122 Posted January 15, 2015 Share Posted January 15, 2015 Very nice project mate there. Am loving the effort you went to to get it all done proper! 2 bar Really? Lol stock internals as well. How long were you running it like that for?Also can I ask what degreasant you used for the head?? Quote Link to post Share on other sites
Ollieh17 Posted January 15, 2015 Share Posted January 15, 2015 Seems like a good place to work!! Quote Link to post Share on other sites
jiggaman_16 Posted January 16, 2015 Share Posted January 16, 2015 (edited) industrial workplaces are the best. Really lovin the rebuild process, top quality parts list. Love what u did with the front face of the plenum on the intake manifold. I'm guessin u bunged the holes with aluminum welding then had it faced off on the milling machine? U relocatin the IAT sensor to the intercooler pipe, right? Thats exactly what i plan on doin soon. I'm assumin the block is'nt notched as yet in this pic, correct? Edited January 16, 2015 by jiggaman_16 Quote Link to post Share on other sites
Turbo Goose Posted January 16, 2015 Author Share Posted January 16, 2015 (edited) Thanks for the comments guys!Calum the reason it went to 2.8 bar was because the vac pipe popped off the wastegate! Kept spinning til it couldnt anymore lol. Didnt realise this until i checked the log on the boost controller later on! Would have only ran it for about 10 seconds i reckon.As for the IAT sensor, i blobed some welds in the holes, filed and wet and dried them, didnt end up using a milling machine as they came up a treat. Then drilled and tapped the back of the inlet for the sensorAs for the block it is notched just that pic doesnt show it very well Edited January 16, 2015 by Turbo Goose Quote Link to post Share on other sites
ro55ifumi Posted January 16, 2015 Share Posted January 16, 2015 Nice update, you running LSD?? Would recommendone once you start with the forged motor, i run my set up on a blue, but if you are at this stage i would upgrade as the ultimate has more areas to adjust the fueling against the blue John Quote Link to post Share on other sites
jiggaman_16 Posted January 31, 2015 Share Posted January 31, 2015 Thanks for the comments guys!Calum the reason it went to 2.8 bar was because the vac pipe popped off the wastegate! Kept spinning til it couldnt anymore lol. Didnt realise this until i checked the log on the boost controller later on! Would have only ran it for about 10 seconds i reckon.As for the IAT sensor, i blobed some welds in the holes, filed and wet and dried them, didnt end up using a milling machine as they came up a treat. Then drilled and tapped the back of the inlet for the sensorAs for the block it is notched just that pic doesnt show it very well U relocated the IAT for a clean look at the front of the intake manifold, correct? Quote Link to post Share on other sites
Jap91 Posted January 31, 2015 Share Posted January 31, 2015 Some very nice work done hereWhat make are them alloys mate? Quote Link to post Share on other sites
Turbo Goose Posted January 31, 2015 Author Share Posted January 31, 2015 Alloys are enkei RS i think maybe another model but deffo enkeis.ye jiggaman i did put the iat at the front or the back depending how you look at it.basically its now facing the bulkhead Quote Link to post Share on other sites
jiggaman_16 Posted February 1, 2015 Share Posted February 1, 2015 Alloys are enkei RS i think maybe another model but deffo enkeis.ye jiggaman i did put the iat at the front or the back depending how you look at it.basically its now facing the bulkheadNice....keep on doin it big.... Quote Link to post Share on other sites
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