Shrikes latest Australian project

[shrike]

Had another 30mins under the car, if I barely thread in the bolts on the rear gearbox mount and tilt the engine forward with the jack etc I can just get it all to line up

Missing a few bolts so will have to wait until I can go to the wreckers to do much more (hopefully on the 15th) and then once I get every thing in place I can start tightening it all up

[shrike]

Quick update

Replaced the low pressure power-steering return hose (brought a roll of the stuff as I couldn't get a short amount) so I can now replace the power-steering fluid when I get some

Motivated to do some more welding after seeing updates of the FC on @rotorhoe instagram and the rust repairs. I brought a tig torch for my Unimig 185 only to discover it didn't fit so will go return it tomorrow.

So I had a go at making a battery clamp as the one I have doesn't fit the battery, still need to clean it up, drill some holes and paint it but itll do the job

Welds are pretty shit but they are solid, worked out I can mig poorly if I actually use the recommended settings for the material I am welding

Due to being encouraged by the above attempt I finished welding up the boot holes, upped the amps and wire speed to match the settings my welder recommended for the thickness of the boot and had greater success.

No pics as I need to clean it up with the die grinder and a file first

Realized part of the reason I was blowing holes was due to not getting enough wire in to fill up the hole (was using the lowest power setting and the lowest wire setting previously)

Still need more practice, I'll be welding base plates to fence posts in the next few weeks so should give me some more time on the welder, hoping Ill be able to do an ok job on the front pipe of the exhaust when the parts arrive

[shrike]

Few updates, will do more after the weekend

Installed the Evo Cas I had, head looks a little varnished :s also need to get a new cam cover gasket but that's a job for another day also need to glue the cambelt cover back together (also going to order a new one)

New inter-cooler turned up its a 530x233x70mm and fits fine with a Lancer rad support, still not sure if evos don't have a support bar there or not (ive got the cut-down ones to use later if I want) just waiting on a piping kit to turn up for it, should do fine with factory TD04HL power

Battery mount all done and installed, need to check bonnet clearance however

Front brake rotors on, Tie rods on (need to tighten the inner nuts) all ready for calipers when I get the bolts

Exhaust gear is slowly arriving, waiting on flanges to arrive before I start mocking it up

200 Cell 3" cat will probably put a 3" flange on the opposite side to the O2 bung

3" flexi to help prevent cracking of my dodgy welds :p (ignore the feet)

Probably do something similar to the below config, will shorten the 90 degree pipe to suit, will have a 2.5" to 3" adapter at the top to suit the factory turbo dump pipe

So will weld the flexi to the cat and the exhaust pipe, have a 3" tri flange on the cat and that will bolt upto my 3" exhaust, I also may get a factory 2" lancer exhaust and put a 2-3" adapter on the end so I can get RWC but will see how I go

Need to order some silicon joiners and alloy pipe to make the radiator pipes

Not sure if I mentioned but I sprayed some start ya bastard down the throttle the other day and it wanted to start when cranking so thats a good sign

Pretty sure it just needs fuel to go, coil has power, injectors have power, MPI seems to be working, can get power to fuel pump when cranking

Once I get it going with the cas thats in it ill see if I can get it going with the other two sensors, also need to see if I can get it running on the Teensy powered Speeduino I have

[shrike]

So quick update, spent 3 hours and a 2hour round trip last Saturday to get some parts

Grabbed fuel lines out of a CC lancer wagon, they aren't identical but with some gentle bending and some new fuel hose I have all the fuel lines in with the fuel tank, just need to hook the return from the engine  to the hard-line and its all done.

Managed to keep the diff in (lowered the rear sub-frame) and get the fuel tank in

Need to bolt the rear abs sensor cables in but otherwise they are hooked up

Bled all the brakes, rear passenger side took ages

Clutch clevis and pin are all in with the clutch all bled, might need to adjust the rod to the master cylinder once I get it running but feels good so far

Have also put a charcoal canister in from the lancer, will have to play with the vac lines and solenoids I have. Not sure if I am keen on having one between the fuel reg and intake manifold :s

Also got one for the Turbo but I may not hook that up at this stage (need to get a t piece anyway.

Will take pics later

Need to put the steering column back in, the passenger side inner guard liner and front passenger wheel (with center cap), put the rear wheels back on

Gearbox, diff and transfer case fluid replacement. Prop-shaft between the diff and transfer case.

Exhaust (I grabbed the 2" one of f the lancer wagon that ill modify for now) 

Front up pipe and cat

Inter-cooler piping

Radiator piping

Front lights, bumper etc

Finish the rust repairs in the back and paint

Fuel (prime the fuel lines), Coolant

Then I think I can start it, bled the cooling system, put a permit on it and take it up the road for a proper wheel alignment as the one it has atm I eyeballed :p it may also need the suspension raising as well

Might need smaller rims/new tyres for a rwc as well but will see what the tester says, still need to put all the interior (Carpet) back in as well

Getting some progress

[shrike]

Really need to take some pics

I have started to fit up the lancer wagon muffler, didn't fit at all but not surprised. Have cut off and then re welded one of the factory mounts. Cut the 2nd factory mount off and replaced it with a bended piece of rod from bunnings. Still got to either extend the last mount or replace it, then cut some more of the inlet pipe to the muffler and the pipe to the flange to get the angles I want.

Also need more rubber exhaust hangers and to see how the rest of the exhaust fits up (need to put the prop-shaft in first) pretty sure itll need to be modded

Still waiting on a 2.5-3" adapter and my 2.5" flange before I can start the front up pipe

Going to get the 2" to bolt up to the front pipe in the same place as the 3" exhaust all going well, once I get it legal ill put the 3" back on and then start to change it to suit what I want. Probably a new rear muffler and an added center muffler to get it to a more reasonable noise level

Front splash guards back on, also managed to get the lower ones from pickapart, need to finish mounting and put the wheel on (the front calipers I got from rock auto)

Other side done with the new center cap on

So much room for brake activities (need to get the ap racing ones back on)

New wiper blades (windscreen needs a clean)


Mounted the resistor pack for the injectors on a bracket I got for the emissions from pickapart as no idea where the factory evo one goes

Got some new return line that I need to hook up-to the hard line (will prime the fuel lines first however)

[shrike]

Rear abs sensors bolted up

Diff fluid changed 

Transfer case drained (bolts don't look the best)

Propshaft in except the centre bearing looks questionable so ordered a new one, I also don't have the hanger mount bushings/bolts so will go to the wrecker this weekend and grab some off an outlander. Haven't tightened the bolts to the diff yet either. 

Will fill the Transfer case up tonight and might do the gearbox fluid as well.

Ordered some 52mm guages direct from Autoguage so will see how long they take to arrive

Boost, oil pressure, oil temp, water temp. I've got a dinslot cover with 52mm holes so will mount 3 there. And I've got two 52mm brackets ill put on the steering surround.

Already have a wideband to go in once I sort the exhaust.

Probably need to go out and get a metal cut-off saw as I am not the best at cutting a straight line with the grinder haha

[shrike]

Transfer case is now full of fluid and so is the gearbox, went to drain the gearbox and it had nothing in it so hoping that its ok :s

If anyones interested 

• Penrite 85w140 800ml in the diff 
• Castrol limited slip 90 500ml in the transfercase
• Castrol VMX 75w-85 2.2-2.4L in the gearbox 

We ordered a new carrier bearing for the propshaft and then realised its just the boot gone on the other side, so ordered one of them too

Had to flip the muffler mount I made as I realized it was too close to the rear tyre, one more mount to weld on and the itll be in place.

Will need to cut the back half of the exhaust off and redo it. Will try keep it looking as factory as I can, will also paint it black when im done

Waiting on reducers for the front pipe before I can start that

[shrike]

So few things happened today

Intercooler pipe kit arrived, so started to mock it up

 

Ordered 2 more 45 degree silicon joiners, also going to get another 2 90degree joiners, also waiting on 1.75-2.5" connector for the turbo

Ill need to cut the straight in half for both from pieces (need to check bumper clearance too ) need to buy a metal cutoff saw as I cant cut straight for shit with a grinder (see the exhaust post under this)

[shrike]

Did some more on the exhaust, still weld terribly, all miged (I have a tig torch but haven't bothered yet)

Muffler is done will put some reflective heat shielding on the bumper as well

My functional but ugly mounts

 

Heaps of space from this mount to the tyre

You will also see my attempt at pie cuts to get the angle for the exhaust right, doesn't leak so no F**ks given

Will probably cut the angle back and get another straighter pipe in to join these two, I also have a little resonator so I may see if that fits there or at the other end of the pipe that is just hanging

Having trouble finding space for the center muffler so going to have to think about how I mount it

[shrike]

Had the 45 degree silicon bends arrive for the radiator, after some cutting down I now have a lower rad hose. just waiting on some tclamps to arrive (might get some temp ones from bunnings)

Still need to do the top rad hose ( probably have to do some pie cuts) and then I can have coolant in the engine

Then intercooler piping and exhaust to sort before I put some fuel in to give it a start

[shrike]

So mucked around with the grinder and welder after work. Also yes my welding is terrible, this was done with my mig, probably shout have pulled the tig torch out but haven't sharpened the electrode 

Also its Galvanised pipe and I didn't get the angles super amazing or tolerances between the cuts perfect but it should work. Will redo it at some point once I get a metal cut of saw and have had more welding practice.

Will clean the welds up and paint them black, pretty sure they are all sealed. My new gauges should be here this week. 

Things to do before I can start it

Reattach steering column 

Powersteering fluid refill

Coolant 

Wire up rad fan

Finish repairs to the fuel pump wiring

Petrol and bleed fuel lines 

Finish inter-cooler piping

Build front pipe

Finish exhaust 

Then before I drive it 

Headlights, Indicators, front bumper  attach rear bumper better (maybe put the tow bar back on), carpet and put the rest of the interior back together 

[shrike]

Not sure why im surprised but plumbed up the cooling system and 

• Leaking drain plug (hoping its just the rubber washer)
• Snapped the expansion hose nipple off so need to replace that (will just get a brass one once I measure the hole)
• The 90 degree pie cut pipe leaks in multiple places so going to redo that :s may have to buy a metal cut off saw. Will also look at what off the shelf options I have 

• Bottom hose seems to be ok and hold water but that's all off the shelf with some trimming 

This pipe seems to not leak though, its still not super pretty however

Also my Autogauges arrived however they probably aren't going to fit with the din slot cover I have so may need to get something else or finally buy a 3d printer

[shrike]

Think my welding is slowly getting better (also seem to have almost chewed through a bottle of gas, might have a leak or left it on or something) remade the top pipe and the new one only have a couple of small pinhole leaks, ordered a 90 degree silicon join so may see if that works

If I feel motivated ill pull the pipe out and go over it with the mig again, really need to get a bench grinder so I can sharpen the tig electrodes and give that ago

3" to 2.5" adapter has now arrived so can have a go at making the up pipe, might do the rest of the exhaust for practice first and do it with a new gas bottle if I run out

Cranked it over the other night to start bleeding the power-steering fluid and to get some water through it, will put coolant in once I sort the top rad hose (will drain the water out tomorrow) wanted to let it sit with water in it to see if it had any other leaks. Waiting on fitting for the rad overflow, think I may have ordered the wrong size 1/4" is too big so ordered a 1/16" which is probably to small, will take the broken fitting into supercheap/repco/autobarn and see if I can get something similar over the weekend

Will do a pic update this weekend, considering going to the wreckers tomorrow as well, partners birthday on sunday so this weekend has a little on

[Regan]

Hey man really appreciate the regular updates on your project. I’m sure if it was a POS micra the geriatrics on here would like it too. Keep it up mate. 

[shrike]

5 minutes ago, Regan said:

Hey man really appreciate the regular updates on your project. I’m sure if it was a POS micra the weirdos on here would like it too. Keep it up mate. 

Appreciate the support, im not very good at some stuff but building the skills up. This is mainly getting it running and tidying it up as I go, somethings will get redone later on. Im also slowly rebuying tools, annoyed that I may have lost some gas though but ill sum it up as a learning experience.

Also having a crack at pie cuts on galv pipe from Bunnings to do rad piping what was I thinking lol 

Will start to get more interesting when its running on one of the factory ecus I have for it as ill then swap to the teensy powered speeduino and see now that goes. Ive had to some questionable wiring repairs that ill sort properly once I know they work, im also limited until I get it registered on what I can do. 

Not after big power but the current turbo will go at some point, thinking a Steve Murch HRC something (35r maybe) but see what he says, need to get an hrc40rs for my nz track car as well.

Considering getting a 3d printer as well, so if I can get my cad skills up might be able to make some things for it. Need to work out how to use a virtual dyno as im limited to road tuning untill I find a dyno to use (but thats all when its running haha)

[tortron]

galv pipe is garbage to weld, i wouldn't bother tbh

 

for the rad pipe you can use silver solder and a mapp gas torch (not electronic solder, you are brazing it) and then use either copper pipe or stainless steel pipe. Both take the silver easily and its melting point is over 800 degrees, and the join is stronger than the surrounding metal.

 

 

People will look at you funny if you use the copper pipe, tho i did it for the lower section when i converted my morrie from thermosyphon to water pump and needed a funny stepdown to work.

You will pick up how to do it in a half hour tbh its dead easy

[shrike]

47 minutes ago, tortron said:

galv pipe is garbage to weld, i wouldn't bother tbh

 

for the rad pipe you can use silver solder and a mapp gas torch (not electronic solder, you are brazing it) and then use either copper pipe or stainless steel pipe. Both take the silver easily and its melting point is over 800 degrees, and the join is stronger than the surrounding metal.

 

 

People will look at you funny if you use the copper pipe, tho i did it for the lower section when i converted my morrie from thermosyphon to water pump and needed a funny stepdown to work.

You will pick up how to do it in a half hour tbh its dead easy

That's a good tip, I used the galv pipe as it was what I had on hand and was more to practice my welding, fully agree its garbage lol. Might have to go get a map torch and some silver solder then will have to see where I can get a length of stainless/copper in 1.25" (32mm). 

[tortron]

Any tube and bend metal supply place will have that, exhaust tubing also as it's a common size. You can get any premade bend or doughnut that you want off the shelf

[shrike]

So went to the wreckers to get the Prop-shaft bushes and nuts (ones on an out-lander are the same) considered grabbing the exhaust of the out-lander as it was 2.5" and a lot closer to the GSR/Evo one then the one I got of the lancer wagon but I was already in to deep with the one I had and didn't want to spend the extra $65 for an exhaust ill use once

And then this happened, it only needed one engine mount unbolted and a few hoses removed, and for $200 I couldn't refuse.

Will put it on the engine stand and get it down to the short block when I have some spare time.

Plan is long term for it so not in a rush, will get forged rods and pistons, along with a rebuild to suit the 4g63 head I have, might aim for 9-10:1 comp but see how we go.

Not aiming for stupid power long term, but a bit more displacement and some more low end torque are never things to object too

Main reason for the 4G69 is I am trying to get away from possible crank walk issues which the 2G RVR 4G63 I have is known for.

I may pick up a 4g64 later on as well, a longer rod motor does appeal, and part of me wouldn't object to running a 4G63 crank in one to get a 2.1 long rod setup

I grabbed the DBW throttle body and the throttle pedal from the outlander as well with pig tails so that long term I can go e throttle the current speeduino I have doesnt support it but ill sort something long term

Bushes and bolts for the prop shaft installed

 

The boot doesn't look super happy but I have a new one to go on when I get around to it, Might be something I use as a reason it fails RWC

Spent way to much time under the car today on the exhaust

Welds are a little better but still shit, again this will be off the car as soon as RWC is done so not phased as long as it doesn't leak

Started making the Front pipe, ran out of CO2 Argon mix when I started it so switched to straight Argon, will go swap the bottle tomorrow/next week. Again not the best welds in the world but they will do till I get a new turbo setup really need to have a clean up tbh 

Started mocking up the 90 degree 3" bend I have but need to cut it on an interesting angle so need to go buy a cut off saw to do that. May have to mod my 3" exhaust as I think its too far forward to allow space for a cat

[shrike]

So, swapped the gas bottle over, brought a cut off saw (with spare disc one for steel one for alloy) and a welding trolley as I am sick of dragging the welder around and want the bench space back.

Put 10L of 98 in the tank to check for leaks and seems to be ok so far, will prime the fuel system once I locate the fuel return clamp ive tucked away and after I remove the snapped bolt in the ac condenser (need to weld a nut onto it) 

Will try get the exhaust done this week/weekend and the intercooler piping may need 2x 90 degree silicon bends to be done but see how I go with the pipe Ive got

Need to tighten all the wheel nuts as well once I take it off the stands

Pics to come in next update

Started on front pipe, cut down the 90degree bend I had, doesnt sit as close to the sump as id like but itll do, cant get it higher without cutting the 2.5-3" adapter which I am not keen to do, even tried piecuts but couldnt get it any higher. Started welding it and had a few blowouts so have ground it back and will reweld it