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FMIC/OC fitting The stealth look! - Ginola's Project thread
As many of you know I have been quietly hoarding parts in various sheds and cupboards for the last few months, much to Handbrakes dismay. Well with the Glorious weather I couldn't have had better luck (other than Handbrake's back going which reduced my coffee supply)!
Lets hope it all works OK! *(puts his giant bag of zip ties down!) I went about removing the front bumper and taking some basic measurements, hard to do as the HDI kit instructions are for a previous version of the kit and don't represent the kit supplied fully.. so mounting points where different. http://i1192.photobucket.com/albums/...ps15850953.jpg Big thanks to CJ who popped by and helped finish chopping the bumper Iron and working out where the 7 different pipes went! :thanx: The core is lightly dusted black with some manifold paint! should cope with heat/chips OK I hope. http://i1192.photobucket.com/albums/...ps3b268b30.jpg I used a bit of silicon pipe for some elaborate beading.. :-|:angst: http://i1192.photobucket.com/albums/...ps5a276a14.jpg After sizing the bumper up I came to the conclusion that the core was sitting too low and took a stab at moving and re-trimming the bumper Iron, http://i1192.photobucket.com/albums/...ps30cd4807.jpg Looked a bit neater and pipes all seemed to fit a bit more snugly...measure 5 times Dave!!!)..:splat: Next day... First things first, I needed to mount the oil cooler. Using a Mocal mounting kit, I chopped it down and sprayed black, using existing holes kindly supplied by Subaru normally used for cable tie holes for fog light leads and air-bag sensor wires, added some silicon hose chopped down for vibration damping. Thank you Karting Steve for the inspiration for the fitment location. http://i1192.photobucket.com/albums/...ps72a3dd0e.jpg Ok time to trim the bumper! This was a bit scary, although I set about doing it with an angle grinder to start with I switched to a Dremel in the end for a neater cut in the tight spaces.. I think I must have sized this up about 15 times, and spent ALOT of time changing Dremel blades! I also had to make a small adjustment to the intercooler core position when I started running out of bumper to cut!! once the position was set I trimmed and re-drilled the mounting brackets for the lower zunsport grill (this is a stealth install after all!) Starting to look decent! http://i1192.photobucket.com/albums/...psd9216048.jpg Sunday dawned and only had a few jobs left to do.. Sorting the cold air feed for the intake and making sure everything was clipped and trimmed back in place where it should be. I managed to get hold of a large rubber snorkel that just so happens to be the exact same size as the intake on the STI front fog cover!! this cant be known to anyone otherwise the price would have been 5 times what I paid for it! http://i1192.photobucket.com/albums/...ps7288f86f.jpg Paired with a 80mm flexible pipe and some zip ties the job was done,.. and it is a nice snug fit!.. You can't really see it in this photo but it is literally right up against the back of the duct on the cover. http://i1192.photobucket.com/albums/...pse6efed08.jpg On the other side I carefully removed the 2 circlips and centre clip to remove the plastic piece and fitted some aluminium grill mesh in its place to protect the oil cooler. http://i1192.photobucket.com/albums/...ps95c2f12a.jpg I also cut up a plastic lid from an old tool box and made a makeshift duct for the oil cooler, I will have another stab at this if it needs more cooling/better channelling after I have seen what the temps are like, needless to say its a bit temporary! http://i1192.photobucket.com/albums/...pse0925aab.jpg After putting it all back together again I had time left to clean off all the little bits of metal sitting all over my car! :shock::polish: http://i1192.photobucket.com/albums/...ps01986b65.jpg I think its turned out fairly well! The main thing is that I have kept my promise to Wanda and not altered the external appearance so she is happy!:yeah: and the stealth look is complete!. http://i1192.photobucket.com/albums/...pse3741970.jpg open the hood!! http://i1192.photobucket.com/albums/...ps549e7afb.jpg Its booked in for some fettling with FB Tuning on Thursday. The oil cooler lines and thermostatic plate (thanks Greg!), 650cc Injectors + Perrin intake pipe and a re-map! Cant wait!.. more to follow. |
Cracking job you've done there Dave wouldn't think you've just fitted a FMIC until you open the bonnet:10:
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+1 on a cracking job Dave :doubleup:
I do hope you did a Ron and cleaned behind the bumper whilst it was off :polish: ;-) Hope Wanda`s back is ok? Perhaps Liz and Wanda could start-up their own `crap back` club? :sadnod: |
Looks very good dave nice and stealth.
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That is extraordinarily stealthy.
Very nice job. |
Good work Dave, how many pints of coffee were consumed in the making:ok:
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:10:
Well done quality work. :doubleup: |
That looks a cracking job mate, really can't tell until you lift the bonnet. Good work! :)
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Great write up Dave - looking good!
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Looking good but where's all the pictures of the scary bit, hacking the bumper about???
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Great write up Dave looks awesome stealth mode
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Cracking job that, well done
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Nice one mate, looks good!
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Great job :doubleup:
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:10:
Cracking Job!! |
Cheers guys for the kind comments, hopefully the results will be decent enough for the work put in, X fingers!
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Good job, I did my front bumper with a Dyney, far less stressful!
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Some have said he's a bit of a tool!
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Haha! ;) |
Very nice job similar to what I have done and you may not need any more ducking on the oil cooler as in the cold weather mine works a be to well.
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very well done
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Great work there and looks very stealthy :)
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http://img.photobucket.com/albums/v1...rcooler016.jpg |
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Very cool! I'd have been cacking it taking a grinder to my bumper! Thought I was brave hacking my grill to pieces :lol:
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Hats to you Dave, a cracking job and not one I would wish to tackle!!!
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No, found an aftermarket one, there is no OEM snorkel down there, as the resonator box that sits in the wing takes all its air from the top snorkel.. I might see if I can nab a few more of them, made from rubber they fit an 80mm pipe |
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Cheers dude ;) Aye those APS ones and the hyperflow monster ones are exactly that...monsters! ;) |
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Cracking job Dave, will come to you if I ever get a front mount on mine :)
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After getting home from the meet today I couldn't resist the niggling bit of the install I had left out completing.. The bottom pipes on the HDI FMIC kits run under the car and as such are a bit of a pain to get sitting neat and high enough off the deck! On my 05 car there are 2 studs for bolting the bottom factory cross brace to..not bolts/nuts they also sit right on the bend path for the FMIC pipe.. causing all sorts of positioning and potential puncture nightmares.
Various instructions on several forums by Harvey Smith(RIP) and other people that have fitted these kits mention turning the bolts round, however on my car there are no bolts but studs.. Taking an angle grinder to these to shorten them down to the height of the nut on them was the only solution, ...(partially deaf now!) Before.. not good! http://i1192.photobucket.com/albums/...psd9633581.jpg After pipes adjusted.. much better! http://i1192.photobucket.com/albums/...ps65ff102b.jpg The exhaust at the back is most certainly lower.. and never gets hit.. so feeling a lot better about the overall fit of the thing now. Engine splash tray re-fitted ;) http://i1192.photobucket.com/albums/...ps6f6e9421.jpg |
Nice job, when is the remap booked?
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Hopefully all ready for Goodwood in a couple of weeks!:whistle::doubleup: |
What an awesome thread! Looks awesome!
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How did it go on Thursday Dave, all good and happy with the results I hope.
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The car goes very well :) Thermal gaskets fitted, injectors, oil cooler etc all working well, looking forward to stretching its legs on Saturday! :) I put 3 or 4 heat cycles through a set of 888s! so should be good fun... .if it stays dry!:paranoid::paranoid: I wouldn't like to guess at power, 75% injector duty at 3bar fuel pressure injectors are flowing at 700cc.. If anyone can do a rough guestimate from that feel free! It took quite a few more degrees of timing at the top with the FMIC fitted :ugeek: |
Some makeshift ducting, ziptied bits of mudflap! ;)
http://i1192.photobucket.com/albums/...psd5ec7374.jpg Some 888s on the track wheels.. The boss said.. "Are those road legal!!" :D http://i1192.photobucket.com/albums/...ps9d554832.jpg |
I bet those tyres have some grip on them Dave .
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Now to see how many track days they last! and if my baffled sump is upto the task of staving off oil starvation ;) I took them of the car tonight as they have done about 115 road miles. I wanted to heat cycle them a couple of times to firm them up a bit in an effort to make them last! |
It looks amazing, and that snorkel ideal is cracking ! wonderful tasteful mods, and great work...
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Just wait til you try the triple 8's on the circuit........
They push the boundaries much farther than you'd expect :) |
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Glad the knocking noise was only something bumping on your shaft.......
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:norty::cath: |
:more:
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Quick update. I thought I would leak test the FMIC prior to getting a new turbo fitted and sort out any remaining niggles with the system so as not to cause any undue problems when mapping.
So off to the local plumbing supplies shop and £1.95 for a 2" waste pipe end. (with rubber sealed cap!) I drilled a hole in it and mounted a nice super light weight aluminium tyre valve in it!.. (hey our pressure test kit needs to be light weight!! :P) http://i1192.photobucket.com/albums/...psd30e9173.jpg I used a tyre pump to apply pressure to the system once I had capped the other end off with an old paint can, some tape and a couple of jubilee clips. I then sprayed over the pipe joins with a fairy liquid and water solution. Much to my annoyance there where tiny leaks at nearly every pipe junction! Indicated by big bubbles forming all over the place, despite the hose claps being tight enough to bend the bolts holding the claps!! I have since replaced the hole lot with Jubilee clips (took 3 hours to do this without removing the Bumper! and hey presto more pressure and no more leaks!!) Annoyed at HDI a little I am! clamps anyone? http://i1192.photobucket.com/albums/...ps4b8a4792.jpg |
good effort. you wouldn't have had time for ps3 today then:ok:
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Are those the clamps that leaked?, if so im surprised as they look a decent clamp and would of thought they'd be better than just jubilee jobbies
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Today I fixed the exhaust rattle + washed it..:polish: Time for PS3 now :five: |
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FMIC/OC fitting - The stealth look!
Fixed the "oil cooler a little warm on track" issue and enlarged the cold air intake to match on the other side..
Got hold of a second hand set of fog covers (so I can obviously still have the stealth standard look when wanted!) I already had a second drivers side cover with a toe eye hole pre-drilled, but missed the passenger fog cover.. (Many thanks BigE!) I spent most evenings this week occupying the shed and using the oven in the kitchen baking paint! much to Wanda's amusement. This was the idea.. fit as big a duct as possible in the cover without making it look REALLY crap! http://i1192.photobucket.com/albums/...ps9e44766f.jpg So sand down with 400 grit and then 600 and prime! bake/prime/bake rub down some more/dry prime/bake! http://i1192.photobucket.com/albums/...psee01d282.jpg Once the Primer was done it was on with the metallic, no rubbing down here other than 1 coat before the end.. Looks pants without lacquer! http://i1192.photobucket.com/albums/...ps7bcc6259.jpg I didn't use a mask 1 night, and my shed is pretty small, the night was painful as was the next day.. so did my best Bane impression the next night.. http://i1192.photobucket.com/albums/...ps6b1c9ef0.jpg http://i1192.photobucket.com/albums/...psfcd71898.jpg Once they have had 5 or 6 coats of metallic and some lacquer they look a lot better.. just a quick flatten with some 2500grit and a quick compound and polish! http://i1192.photobucket.com/albums/...ps694238ab.jpg Not a bad colour match! http://i1192.photobucket.com/albums/...psdf6fbaf1.jpg The finished article. with custom gauze glued in place. http://i1192.photobucket.com/albums/...ps12abce51.jpg The other side was a lot easier, I simply cut the hole pealed the remaining stickers of and mounted the duct.. The end result on the car doesn't look to bad I think.. It should hopefully be very effective, The ID of the ducts is 89mm! http://i1192.photobucket.com/albums/...ps1f030385.jpg Just to reiterate, I still have original covers and am able to swap between the two! ;) . |
Nice work :)
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Looking good Dave
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Really interesting watching the oil temps with this, in traffic on Saturday through Hove/Brighton temps never crept above 91, it just shows some heat escape when stationary also helps rather than having it in a closed off space with a small slit for ventilation. On the run back from Goodwood today being a little fruity with 1 or 2 Supercar's temps never got above 85, really happy! I wasn't sure if I would like the look with the dirty great holes/ducts in the front fog covers but I think I do! Wanda likes it too so all good! |
New front hub assembly ordered :|
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Fitted this a couple of weeks ago to try and drop engine bay pressure to assist cooling, seems to have worked! Just have to hope now it doesn't cause any odd aero effects at 150mph!
http://i1192.photobucket.com/albums/...pslrdu79g6.jpg http://i1192.photobucket.com/albums/...pso9cxsnmp.jpg http://i1192.photobucket.com/albums/...psajoj20zb.jpg |
Interesting idea, have you thought about putting a smaller wrx scoop on?
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Yes, removing it would be the best thing and a reverse scoop / vent but it changes the look of the thing an awful lot |
Go on, you know you want to try a reverse scoop .... :razz:
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(Please excuse the phone quality photos :S) http://i1287.photobucket.com/albums/...ps225bb10e.jpg It came primed, So after a few coats of halfrawds mixed O2C blue and a couple of coats of lacquer a good flatten down and then cut with some compound the result was half decent and will do for now.. this was a lengthy process as it would not fit in the oven!! :( .. A hair dryer sufficed http://i1287.photobucket.com/albums/...ps4ff722c0.jpg And fitted... Colour match is pretty decent.. though hard to tell in these photos.. http://i1287.photobucket.com/albums/...psfc933dc9.jpg http://i1287.photobucket.com/albums/...psc05e32d5.jpg Took the car for a quick blast and the results where very encouraging, water temps stayed low and I noted a drop of about 3 to 4 degrees in intake temps which I was not expecting.. :O I also noted a 4 to 5 degree increase of temps directly above the turbo (to be expected as no massive scoop ramming air over it) but perfectly acceptable. This is function over form!! the scoop is not going anywhere! (The Handbrake will make sure of that!:wife:) but for trackdays were temps get high, I hope this will help pull a bit more air through the rad/FMIC. I will report after the next track day if it helped! if not.. time to chop a WRC style hole in the front of the bonnet! :norty::yeah::twisted: |
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Very impressive Dave :10:
Can I send mine over for a quick 02c spray too ....:-P |
Good job with the reverse scoop but I do prefer the horn back on the rhino xxx let's hope it helps the track days and look forward to the scoop inbetween xxx
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Good job.
Not my bag of rice aesthetically, but if it does the job then it can only be a good thing. The car is there to perform after all! |
I think it looks alright mate and I love the scoops as I've said before. Liking yours though, good work!
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Nice work mate :10:
I really like that.... cracking effort with the paint too, looks really good :) |
Looks seriously good with that grill in place of the vent dude. Awesome looking car.
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Cheers all ;)
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So its been a while since I've updated this thread but thought I'd do a small update,
As many of you know I am paranoid about knocks and slapping noises (not the kinky kind!) but the ones from bores & pistons, and as my car has managed a fair few fairly hard track days.. I am always nice and gentle with it! I felt it was high time to swap the engine out for something a little less.. "used" It would be fair to say that I have more than had my moneys worth out of the current unit with 2 trips to Spa and 3 trips to the ring + various track days in-between, none of which have been done at standard power levels. So the plunge was made the and the bank violated etc etc, I sourced a low mileage JDM STI engine from a reliable local supplier, that was imported in a standard car and went about purchasing the additional bits and bobs required... The shopping list included.. Harvey 3 bolt up-pipe to go with my RCM manifold (that has lived on the office floor for a year!) 11mm oil pump (I like a nice lubed engine!) New gates belt kit, Oil & Filter, Plugs, sealant, Coolant Rear break pads (PFC items), diff oil and a pair of front wheel bearings (I seem to eat these for some reason!) Several ££££s later some time was booked with Richard at FB Tuning for the work to be undertaken and the day of reckoning was at hand! I came over all nostalgic driving the car to the workshop knowing that the engine was coming out of her and how good at had been to me, all the pulls on the autobahn, trips to Isle of Man & Germany etc etc, but at least this way I am saving the heart for a later project ^^ Bits stripped off and getting ready to be pulled! :( bye bye old friend! http://i1366.photobucket.com/albums/...psyha30he2.jpg nooo! http://i1366.photobucket.com/albums/...psuzkf6hwx.jpg Soon to spin again! http://i1366.photobucket.com/albums/...ps17ibev5a.jpg All out in a couple of hours and bits removed an hour later http://i1366.photobucket.com/albums/...psqbulxgze.jpg Much to mine and my wallet's dismay the flywheel and clutch where inspected and deemed to be not worth re-fitting. Looking at the wear on it and the state of the flywheel it simply wasn't worth messing with.. http://i1366.photobucket.com/albums/...ps8w4qwpn6.jpg Some nice cracking! Like I said I am always gentle! http://i1366.photobucket.com/albums/...psdh1g4hbk.jpg So off to Lateral for a new one!:-| a couple of hours later.. http://i1366.photobucket.com/albums/...pswnsst7rk.jpg New oil pump prepared and fitted, new timing belt kit and bits and bobs fitted. http://i1366.photobucket.com/albums/...psn2tnvk0w.jpg With my current set-up there are quite a few bolt ons to swap over including a group N sump which needed quite a bit of cleaning. The jury is still out on this one as to whether or not the Millers 10w60 Nanotech that I've been using doesn't have enough detergent in it or there was some other underlying issue that caused the blackening visible in the next pics. There where sooty deposits all over the place! Sump all cleaned, steamed and then blown dry. http://i1366.photobucket.com/albums/...pstdvg4s8s.jpg http://i1366.photobucket.com/albums/...psnbbmfpxl.jpg Old engine underneath (no windage tray with group N sump!) sooty! http://i1366.photobucket.com/albums/...psjx81qkik.jpg New engine underneath, clean. http://i1366.photobucket.com/albums/...psrdhmpefp.jpg Getting there! http://i1366.photobucket.com/albums/...ps6edpf5az.jpg http://i1366.photobucket.com/albums/...psvci28xin.jpg We noticed this when re-fitting the radiator. Pretty scary and a potential fire risk. I think it had either got very hot just above manifold or something rubbed against it. Repaired, cable moved higher up and sorted with a little mod ;) http://i1366.photobucket.com/albums/...ps0kuohwco.jpg So up until this point everything had going reasonably smooth which as many of you know is not normally how these things go. Well this was no exception with everything re-fitted and nearly ready to go, oil and coolant loaded back into the engine. We primed the oil to get some round the engine, only to discover a big oil leak!! :brickwall::brickwall::shock::splat: Oil was sitting on top of the block and all over the back of the engine dripping down by the turbo! oh noes!! We quickly worked out that the only place that it could be coming from was from the hard oil feed line that pumps oil to the turbo.. this as many of you know is a bit of pig to get to. The world almost ended!! Knowing there was no other choice we set about removing everything off the top of the block (AC pipes, manifold, turbo and water cross over pipe) to find the offending item. We had re-used the original line that came with the new engine but it was sat at the wrong angle for my turbo. We had previously warmed it all up and bent it into position but by doing so we had inevitably cracked it. Not easily visible as the crack was facing towards the block/turbo but clearly visible when removed.:( http://i1366.photobucket.com/albums/...ps9utf1z9y.jpg By the time we had finally got everything back together, once again primed the system, gapped/fitted the plugs, re-filled with coolant and turned the key.... there was an overwhelming sense of relief as she fired into life instantly and oh what difference.. its very quiet, I'm not used to this virtually no slap business :yeah: Somewhere in the above 25 hour marathon I also managed to fit the new rear pads and swap the diff oil out for some nice LS Millers stuff ;) Due to the extra time to remove and re-fit everything we ran out of time for mapping but will get this done in the very near future. Say hello to 8k RPM rev limit and aggressive cam profiles! :razz::yeah::razz::drive::drive::razz::yeah::razz: |
Next day! and home again I got on with replacing the 2 front wheel bearing cartridges,
Not too bad a job on a wide-track you can actually do these in situe without removing the drive shafts at all. http://i1366.photobucket.com/albums/...pss0vkdgwi.jpg Thank's CJ for popping over and lending a hand ;) I also could not live with a dirty engine bay (MANY FINGER PRINTS!) so gave it a quick clean ready for mapping! http://i1366.photobucket.com/albums/...psqicakprl.jpg |
Amazing read Dave! She's one awesome car!!
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Awesome. 👍😀💪
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Nice replacement until you sorce a spec c block in the near future if one ever comes up for sale again .
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Nice work dude. Look forward to going for a spin when it's mapped :)
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Nice, mucho approvo.
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Great job fella & good luck with the map :ok:
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really good read!! looking good!! did you do any further investigation into the millers nano tech,soot issues???
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Good going, think it took me just as long to fit an ARB and fuel pump.
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Looks amazing Dave :ok: - how many cups of coffee were consumed during that work I wonder! ha ha
Can't wait to see and hear the results... Ryan :ok: |
Amazing stuff Dave, great write up and can't wait to hear about the results after the mapping. I never felt what your car was like in its now previous form, let's hope I will get to experience it with its new heart soon!
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Nice work Dave, are you gonna try a different oil?
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Thanks for all the kind comments, I'm still looking into the oil situation, I'm considering switching, if I do it will be to Motul 15/50 but kind of wanted to stick with the soup that is 10w60 as its a little thicker up at high temps.
the old engine had done 1950miles on that lot of oil btw I found this on a thread on pistonheads:- The 'Nano-drive' additive is not the moly, like I say, the moly in the analysis is a soluable form, which the vast majority of engine oils use these days, the Millers is just rather high in it as it's designed really as a competition oil so won't have as many detergents/dispersants fighting for the surface interface (although they do have similar levels to API specs so can be used daily), and doesn't need to meet regulations on phosphorous levels (so can use more ZDDP, etc). The 'nano-tech' bit is actually a tungsten disulphide additive I believe, not moly. |
I've been using the standard 10w60 Millers CFS for years on mine, wonder what it looks like inside :)
But then all the time it works, i'm not bothered. Thats also why I don't have an oil temp gauge :lol: |
Always used Millers Nanotech in mine :ok:
(but then I do only drive at 30mph!) :drive: |
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Schweet Dave :ok: Just to be nosey how many miles has each engine covered?
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I use the 15/ 60 version and not had the blackness you have at rebuild time
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Great read Dave :more: , looking forward to the mapping results :ok:
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Mapped today, more timing, lots more airflow :shock: run slightly less boost (3% less duty) making lots more power :O circa 430bhp was the given guestimate, can turn the boost up more but think that will do for now :)
Seems a fair bit faster, pulls harder than before and keeps going:O seems weird flying into the red line and keep going before changing, despite owning a JDM car before shifting at nearly 8 grand now seems a little alien, Perhaps I need a JDM rev counter.. Quote:
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I think I will replace the current oil with Motul 15/50 when back. |
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Looks like some pleasing results then, when you can claim it 'pulls harder for longer' I think that says it all for a positive result, good stuff.
Getting it out on track will be the real tell tale sign now. |
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