Williard

iTrader: (18)

So as the title says, im starting my build thread.

I purchased a new SSV from another member/Mod to fix an issue i was having. Once i got everything torn down and ready to go i found quite a few things that i didn't like.

So quick backstory, i purchased the car in Killeen TX while stationed at Ft. Hood. The previous owner blew the engine by not putting oil into it. When i purchased the car, the dealership had already installed another engine. He told me it was a new CAT and new engine the whole deal. Compression test showed good numbers so off i went on my merry way. Three weeks later i start having sputtering issue's misfire's and a few other issue's so i get it towed back to the dealer.

They didn't replace the CAT, it hadn't come in yet apparently so that set me off. The clogged CAT killed the engine. So another engine gets put in, same thing, good numbers still waiting on a CAT. Well by this point i have to move to El Paso to Ft. Bliss in about 2 days, can't wait. I take the car and gut the CAT.

Back to present day im having some issue's that i know the SSV would fix. As i start tearing everything down, i notice some clamps not tight and a few other odds and ends that i know i haven't touched just not right.

Whoever maintained this car before me, is a terrible person.

The only other thing that seems odd to me is, i drained my coolant. To my surprise it's orange...Yes orange...Not green like FL22 would be.
The odd part is while in El Paso, just before i was Retired from the Army i had Mazda flush my coolant and replace it. I had a 2k+ drive ahead of me i wanted to be sure it was in tip top shape.

Now i haven't added ANY coolant since. So im curious as to how the people who MADE THE CAR cant' put the correct coolant in it.

Needless to say my entire cooling system is being replaced and im scrubbing chunks of SH** out of the thermostat housing and a few other things.

The pictures are all from my phone, not the best but it's a start.

So everything is clear on what im doing.

The engine will be out shortly.

new(ish) engine
Clean engine bay
Replace entire cooling system
Boost and all the accessories that go with it.
New wheels <---already here just need tires and TPMS
New Clutch
Flywheel
Counterweight
Injectors (blue's are being added)
Suspension
adjust/repair some wiring
and a few other things.

I've also been cleaning up the rust from everywhere.

On a final note, just to keep track. This will now be engine #4 going into my 8.

Williard

iTrader: (18)

some pictures

Williard

iTrader: (18)

more pictures

Williard

iTrader: (18)

Many more pics to come. The only things left to pull the engine are the two mounts and two trans bolts.

It's going to be a long fun winter


Travis

Williard

iTrader: (18)

The wife's Mustang and My 8

9krpmrx8

iTrader: (46)

Glad to see it's being cared for now. Why did you remove the ECu from the box and why do you have it and the alternator just laying there?

Williard

iTrader: (18)

9k,

I took those pictures in the middle of everything. I layed the alternator there so i could strip that crumbling wire loom crap off. I have a few more pics that i will upload to ease your mind. The alternator is off, and the ECU is completely disconnected and safely tucked away in a box. Im bouncing around the idea of moving where the ECU is located. Not 100% sure yet though.

Im really quite unhappy with myself due to the fact of. I drove this car for a while and never noticed a lot of things that could have been potentially bad. Now, i've never actually torn the car down before to this level where im finding the problems but still.

It upsets me that people can rig a car in the ways that the previous owner or the dealership did.

Anywho, as i said i will upload more pictures in a bit. Everything is being fixed. Once i get a cherry picker in there i can pull it out.

Still trying to figure out what im going to use to break those top engine mount nuts loose.

Mabye another 1/2 inch breaker bar with a cheater bar on it..



Travis

Williard

iTrader: (18)

As you can see most of the wire loom crap on the alternator wire is gone. The lower shelf has all the hardware bagged and tagged. Im currently going through every part, cleaning and inspecting to make sure it's all good.

In the last pic you can see the ECU is removed as i said, its tucked away safely in a box.

More pics will come up slowly as i make more progress. I plan on taking quite a bit of time to remove the surface rust in the engine bay.

Stay tuned for the slow but exciting action lol.


Just to be clear, all the "orange" in the engine bay isn't rust. Some is from a bit of coolant going everywhere. If that doesn't make sense, read the first post.

Travis

9krpmrx8

iTrader: (46)

Nice, yeah you realize how things are when you tear them apart. Hence why my engine swap took so long because I basically replaced and cleaned everything I could. That is also why this "turbo rebuild" took so long,

Every time I have here apart it turns into a full on project. I spent my day to today sanding and painting the heater hard lines and a few other things that most would never mess with, My only regret is not fully painting the engine bay while I had everything out like Carbon8 did.

Glad to see you getting to it, I cleaned and redid most of the wiring in my engine bay as well.

Williard

iTrader: (18)

I am doing the entire engine bay. I figure, since it's apart and i have no intention on it leaving my garage until at least May i might as well do it right. Literally the original plan was to install the SSV and boost it. Once i got in there and found the whole mess of junk and then realized i have a small coolant leak in the front rotor housing, it wasn't even a decision.

I am bouncing around the idea of going a different color route for the engine bay as well. Most likely it will stay black though and have some small accents. Im changing the backing plate from that orange to a dark blue as well. The build colors will be Black exterior with blue accents. Im going to maintain my black and brown interior.

Just like you 9K everytime something comes off it turns into a project. Once it's all complete though she will be beautiful again and better than before. I am going to rust proof everything that i possibly can.

Since it is all apart finally, i need to find another hard line for the fuel pump. The line that comes up from underneath to plug onto the fuel pump itself. A while back mine cracked at the line and the elbow of the fuel pump. I cut the end off and replaced the housing. I would really like to have that stock attachment back on.

That will be a little while later though, more than likely i'll have to take a run to Rhineharts to get it.

I'll keep updating the thread as best i can in between work and everything else.

9krpmrx8

iTrader: (46)

That fuel line is not hard to replace and doesn't cost much. I replaced mine.

Williard

iTrader: (18)

I already called Rhineharts about that feed fuel line.

He has Several good lines with low mileage on the cars. That'll do

I save in some area's where it's completely safe and possible. So that i can splurge in others.

Travis

Williard

iTrader: (18)

In the first pic we have just my center console. Everything has been removed I.E. radio, ashtray etc..

I really dont want to rip this all the way down in order to replace the heater core...

Anyway, the gear stick has already been taken out it's just sitting in there for the moment. I dropped one of those little bastard screws down the side of the trans, it's rolling around on my floor under the car somewhere.<Didn't get to check, had to leave for work.

Just noticed in the pic what i did, Before anyone try's to call me on it. LOL, Yes i do know the notch on the gear shifter points to the P/S. And mine is currently NOT. Again, it's just sitting there to cover the hole. lol

Second pic Passenger side airbag and dash cover out, glovebox out.

The third is the fuel pump access....Now, i've already removed this and i just haven't taken the picture of it off yet..

The radio and everything else just loose laying around has been removed.

It's slowly creeping forward but i've been working non stop hours so i dont really have time to work on her yet.. I haven't had off in two weeks. Upside is i have off Friday so HOPEFULLY i'll be able to go get my engine stand and cherry picker! <Fingers FIRMLY crossed that this moron calls me back again.

Anyway, comments welcome. Easy on the Flame.

And party on Garth.



Travis

Williard

iTrader: (18)

Hopefully i'll be pulling not only the engine this week but the passenger side carpet.(heatercore leaked all over when the line cracked) Yes i did shampoo the carpets and everything else but im sure there is stuff i missed. So im going to pull it all and i actually have a small roll of carpet padding. The plan is to clean it completely, remove the old padding and replace it.

Not a hard process at all, just takes patience and a bit of spray glue.

A few other things are being worked on in between and i'll post more pics as soon as i can.


Travis

logalinipoo

some heat shielding down there might not be a bad idea before you melt some carpet with a turbo.

Williard

iTrader: (18)

Log,

First off, hows your build coming? I haven't looked in a bit.

Next, Im actually in the process of deciding HOW im planning on doing all the heat shielding. Yes i want it to be functional. But, i dont want it to be ugly either. I was thinking ThermoTec matting under the carpets so far. Not set in stone of course. I will have all the oil lines and everything else covered.

I'd really like to be able to set up a turbo blanket and have it not look like garbage.

Any other suggestions?


Travis

logalinipoo

The turbo is off at comp. It's going to take another week or so. They said they have a bunch of rush stuff for sema(SP). I'm having it swapped to a billet wheel and going down to a 60. Then end result will be a CT3-6065 ball bearing. It should spool like all hell and have all the boost the car ever needs.

Luckely you don't end up seeing most of the stuff down there unless you're working on the car. I don't think my turbo blanket looks bad, but I can't say how one would fit with a greddy.

Williard

iTrader: (18)

You can always make anything work with enough fab work lol. It's just a thermo blanket, i'll figure it out for sure. I do want to make sure everything is well protected from the heat though so i will take my time on this.

What else is left on your build?

I do like what your doing with the turbo set up.

It's not the fact of seeing it..

Its just i know it's there lol... Either way i'll make something work that i can live with lol.

Travis

logalinipoo

LOL, I know I feel bad about how all my welds look even though I know there not a problem at all for the build.

I still have the piping from the inter-cooler to the Throttle body, I have to finish the water box mount then run water lines and re-install the turbo. the intake piping is ready i Just have it running NA right now so I don't have that piece installed.

I've also got to figure out a fueling problem that has me aggravated and I just haven't felt like spending more time working on it. I probably have 60 Hours or so working on the manifold. To get everything in place just right with good clearance. Most of that was installing and setting the engine on the mounts, then taking it off and adjusting it again. Cutting welds an moving things.

Williard

iTrader: (18)

What fueling problem?

Always just take your time. Dont forget to take a step back and relax every once and a while too. All work and no play makes Travis a pissed off guy so im sure it's the same for you lol. I love workin on the 8 though.

Just helps to have a calm mind. Even if it takes bouncing a ratchet off the door after it slips and you crack your knuckles. Then you scream and scream and cuss.. But after.. Your knuckles hurt.. HA! You thought i was gonna say feel better. Well kinda, you'll be calm, but a bit aggrivated due to the bleeding knuckles.. But the screaming and yelling helped get the clouds outa your brain. <---un needed rant lol

In the end though it's all worth it. It is a SEXY car.


Travis

9krpmrx8

iTrader: (46)

You can see how I redid my heat shielding during this phase of changes in the last couple of pages of my build thread. It is important, I would melt shoes before with just heat coating on the firewall. I found that the ATP turbo blanket for the Genesis fits well, it has provisions for the water lines.

Exhaust Heat Shield | Heatshield Products

logalinipoo

Oh I messed something up with my fuel rail I think. I have taked a 2 week break as of now. When I get the turbo back I'll get back to it. I've already had it close so that will inspire me to get it done.

Williard

iTrader: (18)

So, Friday i had a day off for the first time in 3 weeks. I had a bunch of things to do and didn't think i'd get to work on the 8. Well happily i did. I didn't get to much headway on it but i did get a few things done that i'll upload pics for tomorrow.

I now have the rear seats completely removed and i am currently contemplating removing that "v" brace behind the seats because it seems to have some surface rust that i just can't leave alone. So yea, im going to remove it, wire brush it, clean it, and paint it. Once thats all done i'll re install.

I have the rear speaker covers removed and those tiny tweeters removed from the covers.

I want to replace ALL of the bose crap speakers with better ones. Im not to audio savvy but i used blaupunkt speakers on my 05 Nissan with MTX COMP. 12 subs a 2.5 farad capacitor and a 1000watt amp. It sounded pretty good.

Now i dont want rediculous bass with the 8. Im not really into the rattle your heart bass anymore lol. I want to keep it to a single sub with what will hopefully be a small box i can tuck against the back seats. I actually want to keep the factory headunit for a few reasons.
1- I have had an in dash dvd and while it was "nice" it wasn't any easier and barely got used.
2- I like the look plus the 6 disc is handy.

I would like to add an AUX cable so that i can use my phone for music as well.

Anyone found good replacements for the factory bose speakers?
I.E. That actually sound good and fit.

Do these sizes look right?

Front Mids: 9"
Tweeters are all 2"
Rear mids 6X9<< One is blown must be replaced
Front center is either a 3" but apparently a 4" can fit.

I've also had this nagging issue where it seems at random times the passenger side speakers just cut out. I dont know why...

Im debating replacing the rears and all the tweeters and leaving the front door speakers alone.
Then adding in a single 10" or 12" sub in the trunk obviously a small amp.<<--could possibly come later

Any suggestions for the Aux setup?
http://www.sylfex.com/products/AuxMod/<<---Found this.


Travis

Williard

iTrader: (18)

Just showing a bit more progress.

Im still researching the audio "issue's"

First pic is the back seat torn down, still have to pull that cross brace out to get it cleaned up and painted.

The next three are just pictures of my torn down starter. I ripped it apart last night, cleaned it all up and got it greased.

It's all put back together and moving smoothly. I still need to find another solenoid for it..


Thats all for now.

Travis

Legot

iTrader: (1)

Am I looking at a starter?