Jaffas 2.5 classic Strip and Build
 

For a while now i have watched my oil pressure drop(well that my excuse to the misses)

After driving a 2.5 in a classic couldnt get over how much torque is had and how fun it was.(460/450)

so i just purchursed a Ej257 block and some sti3 heads/cams
my goal is 450/450
md321t turbo witch is a bolt on turbo.
i will be uprating rods/pistions ect i will over spec just incase i want more in the future.
will keep you updated how it gos with some pics.

Re: Jaffas 2.5 classic
 

so far i have 740cc incectors
apexi power fc
rodger clark uprated oil pump
rodger clark light weight pullys
defi gadges
innovate lc-1 wide band
sx fuel pressure reg

Re: Jaffas 2.5 classic
 

striped engine down yestoday.all seems fine nothing out of the ordinary .
new water pump,cambelt tensioner.inlet manafold (to play with) and RCM oil pump turned up today was like christmas

next thing is to strip the heads and and check valve guides etc, then send them away for gasflowing

will get some pics up v-soon

Re: Jaffas 2.5 classic
 

camra is on charge next to my car keys so i wont forget to take it in. :doh:
tomorro :nod:

Re: Jaffas 2.5 classic
 

A very messy engine bay removing old gauges. also removed air con as well.
http://i162.photobucket.com/albums/t...Picture181.jpg

i have fabricated my knock link in my air duct.
http://i162.photobucket.com/albums/t...Picture175.jpg

wires and bits every where at the moment.
avcr in wired in to the ecu wireing.

http://i162.photobucket.com/albums/t...Picture179.jpg

cleaned engine ready for build.

bottom http://i162.photobucket.com/albums/t...Picture185.jpg

http://i162.photobucket.com/albums/t...Picture146.jpg


i have been speaking to mark @ lateral performance about my spec, possibly might get the 2.5 relinered to make it even stronger so i can see over the 500 mark in the future. 8-)

waiting for prices... :ninja:

Re: Jaffas 2.5 classic
 

right i have a twisted turbo kit sorted. just got to spec it to what up pipe size and wastgate size which i dont know:2ponder: i think 44mm wastgate.
hope to be running a gt35r. so dont know on up pipe size:2ponder:
i have recived more braided line to carry out the parallel fuel mod.i also have received the rest of the timing belt gear 3 more guide pullys.

http://i162.photobucket.com/albums/t...e/000_0008.jpg

Re: Jaffas 2.5 classic
 

also in pic thermo inlet manafold spacers. these will lift the manafold higher so i can squeze the turbo pipe underneath the inlet manafold and will stop heat soak into the manafold as well. :)

Re: Jaffas 2.5 classic
 

didnt say what pipe is going under the inlet manfold.
:paranoid:


somthink like this

http://i421.photobucket.com/albums/p...1/DSC00025.jpg

Re: Jaffas 2.5 classic
 

big thanks to wayne for my manaflold.
dont think he is going to do any more due to the 16hrs it takes :whistle: pic dont do it justice.


http://i162.photobucket.com/albums/t...e/100B0380.jpg

http://i162.photobucket.com/albums/t...e/100B0420.jpg

Re: Jaffas 2.5 classic
 

A few more bits in the bedroom now :D
had a slight issuse with scooby clinic with headers i bought off them but i came out of it quite well;)
http://i162.photobucket.com/albums/t.../daryll003.jpg

http://i162.photobucket.com/albums/t.../daryll004.jpg


also got kevlar timing belt from the clinic
http://i162.photobucket.com/albums/t.../daryll011.jpg


also some bling billet fuel rails got them off fleabay very cheep as someone had bought them for the wrong year car:D
http://i162.photobucket.com/albums/t.../daryll009.jpg

and still waiting on swirl pot. and a few other supporting mods.:thumb:

Re: Jaffas 2.5 classic
 

hi nige i am changing all tensioners and guide pulley as a precaution as well as the water pump. the ones on my 2.5 were ok no play not nosiy but not worth the risk.
as for head gaskets going for 1.6mm and been told to aim for 8.35:1 compression ratio

i am going for 1-5 ppg straight cut box and a OS Giken twin plate clutch (comes with its own flywheel)

aiming for the 500 mark but anythink over 450/450 with quick spool is my main aim.


my next steps will be sorting my sti heads out new valves/springs/retaners/ and port and polished/ shimed up. going for dh22 cams and rcm pullys :norty:

Re: Jaffas 2.5 classic
 

just purchased some cusco coilovers, think they may be very hard but will give them a go. :whistle:

Re: Jaffas 2.5 classic
 

still buying parts dam rcm website should of gone out drinking:squint:

WRC Titanium Valve Spring Retainers
set of Uprated Valve Springs
changed injectors to some 740cc witch have been flow matched by lateral to 800cc aslo have got samco inlet pipe and k&N filter fot the gt35 its 4inchs internal diameter.:eek: also got a power steering reservoir relocation kit.

Re: Jaffas 2.5 classic
 

more parts ordered today from rcm should soon have enough to start the build.

so i got
RCM Alloy/Steel Vernier Pulleys
1.6 Steel Head Gaskets.
14mm WRC Up-rated Head Stud Kit
RCM 14mm WRC Head Dowel (x4)
acl main bearings
acl bigend berings

just over 1500quid before breakfast :whistle:

Re: Jaffas 2.5 classic
 

this is a vf24 turbo compered to the inlet hose of a gt35r should be big enough :whistle:

http://i162.photobucket.com/albums/t...e/DSC00051.jpg

Re: Jaffas 2.5 classic
 

saturday i had a easyish day so i thought i would strip my heads and get them cleaned up ready for gas flowing ,bigger valves and the the head bolt holes machined to take the bigger head studs and dowls.

heads complete

http://i162.photobucket.com/albums/t...p-tone/057.jpg

http://i162.photobucket.com/albums/t...p-tone/066.jpg


remove cams

http://i162.photobucket.com/albums/t...p-tone/058.jpg

pull out bucket (see shim underneth)

http://i162.photobucket.com/albums/t...p-tone/059.jpg

compress valve spring remove collets unspring gently else you spend hrs looking for the lost collets

http://i162.photobucket.com/albums/t...p-tone/063.jpg

this it the vavle the valve spring the sping retainer and the 2 collets

http://i162.photobucket.com/albums/t...p-tone/061.jpg

repeat 16 times lol then washed them in the wash tank
http://i162.photobucket.com/albums/t...p-tone/067.jpg

http://i162.photobucket.com/albums/t...p-tone/068.jpg

Re: Jaffas 2.5 classic
 

so bit of an update with a few pics of some goodies which arived this morning :yeah:

pas relocation kit

http://i162.photobucket.com/albums/t...e/100_1335.jpg

Alloy/Steel Vernier Pulley Set

http://i162.photobucket.com/albums/t...e/100_1322.jpg

14mm/14mm headbolts maybe a tad over kill? :paranoid: will dowls

http://i162.photobucket.com/albums/t...e/100_1317.jpg


Set Of 16 WRC Titanium Valve Spring Retainers
Set Of 16 Uprated Valve Springs

http://i162.photobucket.com/albums/t...e/100_1311.jpg

http://i162.photobucket.com/albums/t...e/100_1314.jpg

head gaskets/acl main bearings/big end bearings

http://i162.photobucket.com/albums/t...e/100_1321.jpg

http://i162.photobucket.com/albums/t...e/100_1307.jpg

Re: Jaffas 2.5 classic
 

right from monday i have a week off work, i also have brad down helping me, we plan on striping the inside out ready for the roll cage to be fitted, witch i hope turns up this week. not sure wether to run the car with carpets etc or to strip it out. the cage is a 6 point omp bolt in jobbie so still can retain the rear seats if i want.

also may even open the bonet and remove stuff ie engine.

also now looking a hydra ecu comes with mafles set up /knock control/anti lag/lanch control and seem to be a very good price. just dont know any one useing one :confused:

Re: Jaffas 2.5 classic
 

the weather is getting nice now so i can have a few evenings in the sun with it :doubleup: hope the roll cage turns up this week so the bodyshop can get it painted. :norty:

Re: Jaffas 2.5 classic
 

its like xmas most days lol

so today me and brad started striping the inside out ready for the cage to turn up, as we were distroying my car it arrived :D
most of the problems were down to my alarm systum, due to a very good install(too good:susp:). but other than that wasnt too bad.

i have been thinking for the last few weeks weather to have it striped or full interior. after removing a few things today ,I have decided to strip right out. so i have aranged with the body shop soon as i have striped fully and welded cage mounts and removed sound proofing, the inside is going to be paited in 406 silver with a bright blue cage:D

so while brad was cutting lots of wires:eek: i was chiping off sound deadaning, witch is a crap job:squint:

few pics


http://i162.photobucket.com/albums/t...e/100_1350.jpg

http://i162.photobucket.com/albums/t...e/100_1351.jpg

http://i162.photobucket.com/albums/t...e/100_1356.jpg

http://i162.photobucket.com/albums/t...e/100_1353.jpg

http://i162.photobucket.com/albums/t...e/100_1363.jpg

http://i162.photobucket.com/albums/t...e/100_1367.jpg

http://i162.photobucket.com/albums/t...e/100_1361.jpg

http://i162.photobucket.com/albums/t...e/100_1362.jpg

Re: Jaffas 2.5 classic
 

an update from todays effort stripped more!! and removed more sound crap!!!
i got the cage back in to start a dummy run to see where i need to weld the brackets.
http://i162.photobucket.com/albums/t...e/100_1416.jpg

http://i162.photobucket.com/albums/t...e/100_1419.jpg

front bracket
http://i162.photobucket.com/albums/t...e/100_1421.jpg

rear bracket.
http://i162.photobucket.com/albums/t...e/100_1420.jpg

Re: Jaffas 2.5 classic
 

its booked in on the 23rd at the bodyshop for them to work there magic. i booked the day off to help them if needed :doubleup:

Re: Jaffas 2.5 classic
 

i booked thursday off to help fitment of cage in bodyshop, but they are running behind so now in monday
as i had the day off i attacked the last of the sound deaderning, then started to wipe down inside to get the gule/yucky stuff off useing thiners(not a good idea! car was in the sun i am kneeing on the floor with doors shut i passed out 2 times before i could manage to open the door,when i got out i was high as a kite. :whistle:

a couple of pics how it looks..
http://i162.photobucket.com/albums/t...e/DSC00121.jpg

http://i162.photobucket.com/albums/t...e/DSC00122.jpg

Re: Jaffas 2.5 classic
 

car went to the bodyshop today:D we are modifying the brackets as they done fit that well imo.
will get some pics up of that up soon.


as i am doing away with the A/C i have removed the a/c matrix witch is quite heavy! also blocked up holes useing soldering iron.
this is the unit
http://i162.photobucket.com/albums/t...e/DSC00125.jpg

taken apart
http://i162.photobucket.com/albums/t...e/DSC00126.jpg

back togeter with holes
http://i162.photobucket.com/albums/t...e/DSC00127.jpg

then filled in
http://i162.photobucket.com/albums/t...e/DSC00130.jpg

on the mission to remove as much weight as poss:D

Re: Jaffas 2.5 classic
 

Body shop has finished for now;) the brackets are all welded in.
rear bracket tacked and drilled
http://i162.photobucket.com/albums/t...e/DSC00136.jpg

welded rear
http://i162.photobucket.com/albums/t...e/DSC00137.jpg

center
http://i162.photobucket.com/albums/t...e/DSC00138.jpg

front
http://i162.photobucket.com/albums/t...e/DSC00139.jpg

i managed to get the dash support bar back in and the dash back on ready for cutting:norty: hopfully i will do a neat job:squint:
http://i162.photobucket.com/albums/t...e/DSC00140.jpg

when the cage fits around the dash i will send it away to be flocked. and back to the bodyshop for some paint:nod:

Re: Jaffas 2.5 classic
 

i have cut the dash :eek: it hasnt come out too bad:)

i made a bit of roll cage up as a dummy to help mark where i need to cut.
the white marks are tipex so i know where to trim.

I did speck to dyney about a spare just incase:haha:

http://i162.photobucket.com/albums/t...e/DSC00156.jpg

http://i162.photobucket.com/albums/t...e/DSC00164.jpg

http://i162.photobucket.com/albums/t...e/DSC00168.jpg

http://i162.photobucket.com/albums/t...e/DSC00166.jpg



also have a few more things arive
oil modine
cool running thermosat
goodrigde fittings (stupily expensive by the way!!!!)
044 fuel pump
swirl pot
steering wheel+boss

http://i162.photobucket.com/albums/t...e/DSC00161.jpg

http://i162.photobucket.com/albums/t...e/DSC00157.jpg

Re: Jaffas 2.5 classic
 

been a while since i updated this, so i met a guy in a carpark gave him my brand new headers and my full systum exhaust and some money, apranently he is going to make me up a twisted turbo set up for me lol(he will and i am very sure of it) just a bit strange handing over all the stuff not knowing him apart from a few PMs lol. i am having a twisted turbo set up to take the GT35/40 T3 flanges also having a screamer pipe off the exturnal wastgate but also a small link pipe made to fit back to the down pipe if its too noisey. :whistle:

The roll cage is in primer the car is on stands wheels are being refurbed and painted the same colour as the cage hopfully this week.
i am on holiday as of next week. i plan to finish cleaning uderseal off carry out seam welding and start to prep the inside for paint(colour unknow) poss audi white?? its in for the inside to be painted on the 20th i think. the dash is ready to be sent away to be flocked just need to wrap up and arrange for collection..

i am currently saving up for a few big things turbo,clutch,gearbox.

engine displacemant is still unknown. was going for the ej257 but wont be strong enought for my needs and future goals. i know i am still useing sti3/4 gaflowed heads with dh22 cams and rcm pullys. i will choose engine cc/ type last thing as i dont want an epensive engine laying about collecting dust.

hopfully have some pics for seam welding, colourfull wheels and cage soon :nod:

Re: Jaffas 2.5 classic
 

started the seam welding:) hopfully will be painted this time nex week!wheels are in primer :doubleup:

http://i162.photobucket.com/albums/t...e/DSC00014.jpg

Re: Jaffas 2.5 classic
 

wheels http://i162.photobucket.com/albums/t...e/DSC00233.jpg

cage in oven ready for paint
http://i162.photobucket.com/albums/t...e/DSC00234.jpg

Re: Jaffas 2.5 classic
 

no comment steve :whistle: lol would like to aim for the next ring trip :doubleup:

roll cage painted

http://i162.photobucket.com/albums/t...e/DSC00235.jpg

http://i162.photobucket.com/albums/t...e/DSC00236.jpg

http://i162.photobucket.com/albums/t...e/DSC00238.jpg

Re: Jaffas 2.5 classic
 

a pair of these should turn up tomorrow
http://http://www.driftworks.com/cat...7fa15ff2dde4b6

also a solution to a problem witch has been buging me. the roll cage goes throu the dash and out throu the bottom there the bonnet relese goes , so i have bought these (locking of course)
http://www.driftworks.com/catalog/produ ... -pins.html

Re: Jaffas 2.5 classic
 

pic of the wheels from the right side.
http://i162.photobucket.com/albums/t...e/DSC00052.jpg

turbo kit nearly done. sitting on the up pipe is my gt35/40r turbo

http://i162.photobucket.com/albums/t...tone/Turbo.jpg

i have also brought a tial 44mm external wastegate

been spending again
Lateral Performance high capacity big wing sump, with RCMS catch can, oil cooler with pipes and take off and Forge Alloy strut brace to hold the catch can.

Sump has been modified so it has a port for a temperature probe, and also has a -10 male for the catch can return. Sump, together with oil cooler holds about 7.5l

Catch can has been modfied to have a -10 male for the return to the sump (-8 as standard) and goes through braided lines to the sump via an Earls one way flapper valve which stops oil flowing back up into the catch can.Hoses have also been fire sleeved.
Forge alloy strut brace, which has a boss welded on to hold the catch can, so the can sits up nice and high.

1200 notes :)

finished the seam welding today will be in the bodyshop next week for paint:thumb:

http://i162.photobucket.com/albums/t...e/DSC00046.jpg

right as normal things dont go to plan... was due in for paint last week, then we decided on some mods to the boot floor. witch is in the prosses of being cut out and doing a flat boot conversion. will have some pics on wednesday

the idea of this is to lose some weight, easer to mount fuel set up on a flat floot:norty:

pics of the boot being cut out, no turning back now :sadno:
http://i162.photobucket.com/albums/t...e/DSC00089.jpg
http://i162.photobucket.com/albums/t...e/DSC00084.jpg
http://i162.photobucket.com/albums/t...e/DSC00086.jpg

:roll::whistle: still on it
http://i162.photobucket.com/albums/t...e/DSC00107.jpg

few more of tonights work..


inner wheel arch is now atached to the chassis leg
http://i162.photobucket.com/albums/t...e/DSC00113.jpg

rear pannel cut away
http://i162.photobucket.com/albums/t...e/DSC00111.jpg

ally angle piece for the new floor to sit on
http://i162.photobucket.com/albums/t...e/DSC00116.jpg

started to make a template
http://i162.photobucket.com/albums/t...e/DSC00117.jpg

http://i162.photobucket.com/albums/t...e/DSC00118.jpg

the boot floor will remain flat. i have been thinking about having a defuser like the zen car, just not sure about the exhaust as most of the cars who have a big ally defuser run front mount turbo set up

started to strip the engine bay got rid of the abs unit, also started to dummy up for the rotated inlet manafold, moving the aulternator to one side etc
http://i162.photobucket.com/albums/t.../DSC001332.jpg
http://i162.photobucket.com/albums/t.../DSC001302.jpg
also a pic of my seat belts
http://i162.photobucket.com/albums/t.../DSC001292.jpg

he was well supervised:wink: should have some more pics mid week hopfully with a flat boot.
looking at battry recolation kits :)

just brought a 6 speed gearbox very very good price:doubleup::-D

not even sure if it has dccd :whistle:

the solaris s6 cant drive it directly its needs a high current driver = small little circuit, if i wanted just to open the diff i could just wire it to the handbrake switch ie 1 click on the hand brake opens the diff witch would be ideal for manovering or wire it into the origianal controller. once set up i dont see why the dccd cant be controled by the CAL switch useing tps and vehicle speed ie turn switch to number 6(tecos carpark mode)

6 speed box next to a 5 speed. box has come out of an MY05 STI
NOT dccd but cant complane for the money i paid:squint:
http://i162.photobucket.com/albums/t...e/DSC00150.jpg

template has been made and been copied into the compusite alloy.
http://i162.photobucket.com/albums/t...e/DSC00154.jpg
http://i162.photobucket.com/albums/t...DSC00156-1.jpg
http://i162.photobucket.com/albums/t...e/DSC00158.jpg

iam in no rush, trying to do it with out owing any money to the bank so once built iam not still paying for it 4 yrs later.

this weekend i will mount the 6 speed in and make sure it clears,some people say you have to fetttle the tunnel others say they fit ok,so i thought before it gets painted inside i will do a dummp up.

no credit cards this project is being paid as i go i got my credit card sitting next to me with a 8 or 9k limit but not touching it.

cheers for the heads up on the prop found someware i can get them for £100 and i need 2 so hoping he might do a deal:smile:


6speed=sooooo heavy:(
I have fitted the 6 speed as a dummy run, . i didnt want the inside to be painted and then have to attack the tunnel with a hammer:fight:
It fits!! its a bit tight :shock:

have some pics will put up later

will get some better pics of box(done on phone in the dark)
http://i162.photobucket.com/albums/t.../DSC001672.jpg

powersteering relocation kit done
http://i162.photobucket.com/albums/t...DSC00161-1.jpg

also carldavey thottle body wedge is being welded on my shiney manafold
http://i162.photobucket.com/albums/t...e/DSC00165.jpg

floor is in :yeah: its not staying red thats the colour it came in..
http://i162.photobucket.com/albums/t...e/DSC00173.jpg
http://i162.photobucket.com/albums/t...e/DSC00176.jpg
http://i162.photobucket.com/albums/t...e/DSC00175.jpg
http://i162.photobucket.com/albums/t...e/DSC00177.jpg
http://i162.photobucket.com/albums/t...e/DSC00174.jpg

also started cutting the loom about getting rid of anythink not needed:
http://i162.photobucket.com/albums/t...e/DSC00171.jpg

lol steve not alot ;)

cut away the rear parcel shelf as its being covered in ally
http://i162.photobucket.com/albums/t...e/DSC00183.jpg

also took some weight out of the boot lid
http://i162.photobucket.com/albums/t...e/DSC00185.jpg

i have these for the boot going to have these on the top corners and make up a drop the boot in and on sort of systum

http://i162.photobucket.com/albums/t...ch_locking.jpg

The rear sceen is out now as it willl be easyer to cut out and make template for the ally parcel shelf/firewall, also there was some rust coming throu around the window so this can now be preped :
http://i162.photobucket.com/albums/t...e/DSC00188.jpg
http://i162.photobucket.com/albums/t...e/DSC00193.jpg