Shrikes latest Australian project

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So interesting day

Primed the fuel line and had some fuel come out of the fuel filter inlet, so tightened that and all good, forgot to unplug the cas so even had it running briefly (oops) was trying to see if I could get my old pressure gauge to work. Ive used a tee on the factory oil pressure sensor in the oil to water housing and put an oil temp and pressure sensor there. I know it had oil in it as it came out when I pulled the factory sensor out. Not sure how long itll take to refill the tees, know it feels healthy so may just send it

Did some more to the front pipe still not as high as I would like but oh well

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Haven't taken a pic yet but did some more to the 2" part of the exhaust but I am out of pipe so will need to get some more

Front pipe will next get the cat which is angled and as tight to the sump as I could get it with the 02 Sensor to come out under the Transfer case, looks like the flexi won't fit unless I put it further back. Need to see how much 3" pipe I have to do that, need to tack the cat and also add a bracket for it to hang off the front k frame exhaust mount

Think Ive semi work out the front inter-cooler piping (its a little tight however) need to tighten it all, make a lower mount for the inter-cooler. Also need to get some fiberglass so I can extend/repair the bumper so that it mounts to the Lancer bumper support

Still need to in order to start properly

• Rear passenger side center cap and wheel on
• Front passenger wheel on
• Tighten wheel nuts
• Finish exhaust
• Finish inter-cooler piping
• Sort top rad hose
• Sort overflow nipple for Radiator
• Replace water with Coolant
• More fuel (10l)

Then before I drive it

• Check all bolts
• Jumper leads
• Tow rope
• Someone to follow
• Bleed Cooling system of air 
• No rego permit
• Check lights all work

Will get it a wheel alignment before I do much driving

Then before RWC (In no order)

• Height adjustment (100mm off ground at lowest point, probably go 105mm on the front pipe to be safe) (Probably do with wheel alignment)
• Soften the dampener settings on the coilovers
• Grind down welds on rust repairs, sand and paint (also under-seal)
• Put carpet back in
• Make sure the interior is all together
• Reattach tow-bar
• Make sure all panels are secured properly

I think that might be it :p

 

 

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So turns out the factory exhaust on non turbo lancer wagons that are similar chassis to evos is smaller then 2" its 42-3mm which is like 1 5/8" I think so massive restriction lol

I can probably make my 2-3" adaptor work with it and I've got some 3" pipe ill use so should be able to get the exhaust done soon. 

Wonder what the RWC guy will think, clearly should have taken the Verniers with me to the wreckers and looked under a few mitsubishis for something to modify to work (and I may still do this) 

Hopefully its quiet though 

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Pics aren't the best but pulled the welder out again

 

Did one more pie cut after this and then I can just run a straight and the flexi with a flange onto the 3" exhaust I have for it

The 3" exhaust I have is questionable both from a mounting perspective and just how its built

Wish I could weld better as the front pipes looking ok, itll get remade when I get a new turbo however

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So almost finished the front half of the exhaust, its raining here in sunny Melbourne land and after having a go at lift arc tigging (DC) some intercooler piping off cuts I cracked it and went back to the mig and the exhaust

Welding isn't as good as some of you guys on here but I had some good runs on this, and considering its a mix of stainless and mild steel dont think I did to bad. Main issue was I started getting a good result and then sped up, need to keep going slow I think

Also need to remember that some of the connections are on and angle and not just weld a straight line

 

Some more close ups

Also going to get a few meters of 2.5" piping and do the inter-cooler piping in pie cuts as I wasn't happy with how the alloy piping was shaping up

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Went to go pick up 6m of 2.5" 304ss pipe from a supplier over here, cost me under $100aud, plan was to put it on my wagon roof racks.

Allowed 1.2m of overhang on the front so with a 4.775m wagon I was only 25mm off, was started to strap it on (it was overhanging the back as I was going to move it forward once I had it a little more secure) and the warehouse manager came out and offered to get it delivered as he wasn't happy with me taking it on the roof. Which is fair enough, a little embarrassing though, they had offered to cut it down for me as well but I thought it would be ok before it came out. To be honest once I got it on the car I agreed with them as I had forgotten how long 6m is, next time ill get it cut in half/thirds or delivered to start with.

I had taken the grinder with me encase I needed to cut it down as well, but lesson learnt. Should be here this afternoon so might do some piping tonight if I am motivated.

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6m is a lot of 2.5" pipe, already started cutting it up, have 2 straight ends (already cleaned up) coming out the intercooler 2 pie cuts to the passenger side and a straight with a 7.5° angle on the end 

Also cut a few more pie pieces, that I need to clean up. Other side needs 3 pie cuts to start before the straight 

Haven't tacted anything yet will start once I've cut a few more bits

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So more time cutting and cleaning up pie cuts gets me to here with a little welding thrown in

Also the pie cuts are 7.5 and 7.5 degree so a total of 15 degree per cut roughly 20mm top and 10mm bottom when I cut them well, do have slight width ranges but I am getting more accurate

Tacking Tacking, Nice and tight (as tight as I can go without worrying it will rub

90 Degree silicon bend so I can remove piping easily

Test fitting the bumper for clearance before I start to weld it up

Heaps of space

 

Started welding the pipe that goes though the guard liner the angle is roughly 75degrees and then has a 30mm piece of straight welded on this goes into the 90 degree silicon joiner that's attached to the front pipe

Welds aren't the best but they will do, shouldn't need to run a bead on this one as it should go far enough for the weld already on it to help hold it on with the T clamps

 

Need to get the front pipe welded up then will clamp this all together, put the up pipe for the turbo back on and start doing the pipe up to the turbo

Haven't started the other side yet but it should be similar, debating if I use the 45 degree alloy pipe I have over the gearbox and then make a stainless pipe from there or not

I have some gold wrap to go on the piping in the engine bay anyway

Also I am using normal mig wire so will either put some clear over it once I clean it up or will paint it black, went with stainless as it was cheaper then the mild steel I could source and is just all around nicer to work with

Need to get some mesh for the bumper as well

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Small update, rad overflow nipple arrived and it fits so that's all attached

Also have a bsp to npt adapter arrive that im trying to decide if I use it

Popped to Reece's plumbing and got a 90 and 45 degree copper bend cut down the 45 degree silicon joiner I had and bobs your uncle

Looks alittle ghetto but seems to work, just has water in it for now while I wait to see if it leaks, will do coolant when I'm happy

Few things to do still and then get it started 

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More inter-cooler piping, tack tack

Making pie cut angles for the inner guard pipe

Inner pipe, just need to weld it up

 

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Getting there 

Will weld up the last if it over the weekend and then start in the pipe upto the intake

Still waiting on a 90 degree 1.75" to 2.5" for the turbo outlet, might see what I can maguver though 

More pie cuts to clean up

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So was at a mates on Saturday putting farm fencing up so didn't do much this weekend, Sunday was doing housework as I am looking after a 2nd dog as of Wednesday for two weeks

Managed to put the bonnet back on and clean the windscreen, also got the wiper squirters going, had to cut the factory plug as I am running two solenoids off the one plug, I don't have a rear washer but the washer bottle has two outputs, loom I have has wiring for two washers but already had been cut :s

Maguyvered piping out of the turbo, will be replaced when my 1.75 to 2.5" 90 arrives 

Intake piping just needs me to finish the 90 degree and cut back the straight pipe some more, wish I had another 90 degree silicon but no one has stock/won't arrive till after Xmas so I'll make do 

Exhaust needs a very small amount of work for the 3" setup to be done

Had it running briefly as well and shes loud, (no vids as I had to hold the accelerator down to keep it running) oil pressure gauge still isn't reading pressure so thinking it might not be the best spot for it, may move it to the head but will sort that out later

Had some belt squeal so need to adjust them once I get the intake pipe done and get it to idle. Also have a small gearbox oil lead that I am not sure where its coming from so that'll be fun to find. Only started since I started the car/its been hotter here (30C+)

Might be able to move it under its own power all going well this weekend, also if the factory ecu I have shits me too much ill swap the speeduino into it

Now with headlights/indicators (really need to order some orange ones. I forgot the tab on the passenger side is broken) Ive got another set that have cloudy lenses, might need to swap some lenses over

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So sorted the intercooler piping, some ill redo later on. Have kind of worked out how to finish the 3" exhaust just need to tack it up to check then weld it up.

Started it again, no video as I was distracted by the return line by the tank leaking so fixed that. 

Managed to get it to idle (poorly) its hunting  and barely registering on the rev cluster by turning the stop screw in alittle. Oil pressure came up on the gauge finally after a few seconds at idle so happy with that. Still alittle smokey but could be a few reasons for that 

Need to put the fuel pressure solenoid lines back on, finish the exhaust, fill it with coolant rather then water, set the idle. Get it upto temp as I'm not sure if the idle valve is working

Will get some more fuel soon so I can set the idle and will take a video then

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Finished up the exhaust, need to weld the other side of the flexi but it all fits up ok, need to check for leaks as well, but have to get new gaskets and some RTV ultra copper for it

Still need to do the adapter to the 1.75" exhaust as well, Tomorrow I have another dog visting for a few weeks so will be tidying up and doing yard work etc

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Started first turn of the key!

So its a little loud still and smokey but I am guessing the smoke is from the shit burning off, think there was some oil residue in the inlet pipe as well. Also think its over full of oil so need to address that too.

That's from stone cold, sounds like its starting to sort itself though, think I need to tweak the idle a tiny amount as its pretty low and see what its like warm, need to add coolant. Had to stop it as I had a leak from the return hose at the top of the fuel tank (all sorted now)

The belt squeal is from the power-steering belt as it needs to be adjusted, oil pressure looks ok, vacuum looks ok considering how low its idling

Probably need to put a timing light on it as well

Thoughts anyone?

 

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Ordered a digital timing light so I can check the timing, should be here by by the 21st

Will order some exhaust gasket and buy some RTV 

Need to do yard/house work of the next weekend/week so will get that sorted

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Timing light arrived today 

Had a quick go but may have grounded the wrong wire on the fire wall so had some melting cable oops

Found the correct plug now

Also helps if I put the pickup the right way around on plug 1 ha

Need to sort the exhaust gaskets so I'm not smoked out when checking it however. 

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So the plot thickens

Had it running today to warm up to check the timing worked out the oil pressure sensor isn't hooked up properly, and that I had plugged the wrong water temp plug in so didn't have a reading on the dash 

Burnt off a fair bit of shit from the exhaust (oil finger prints etc) and the fresh exhaust paint from the heat shield.

Timing light didn't show anything on the marks, realised its showing quite far back so really retarded (probably about 20degrees) tried adjusting the cas without much luck but suspect its out a tooth on the Cam belt as the marks aren't flat but close, also checked it was at tdc by putting a screw driver down plug one and turning it by hand.

Turned it off and went to restart and haven't had it running on its own since, battery is on charge now as it cranks, starts briefly and then just dies/locks up.

Plugs are really fouled (its clearly running rich) and had fuel vapor coming out the plug holes, swapped plugs and got it running briefly after a small bang, but still won't idle.

Have swapped back to the other cam/crank sensor and will have another go tomorrow or later in the week

Really getting frustrated, considering putting the speeduino on for more diagnostics. Might need to realign the cambelt but really not keen 

 

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Tired the 2g rvr cam and crank sensors , which may not work with the ecu I am using as the car wont start at all with them

Swapped back to the evo black cas and it will run just not idle, think I may have tweaked the bliss incorrectly trying to get it to idle as it now just dies

Annoyed as I had it idling nice for part of yesterday :S

Might spend more time on it this weekend, need to adjust the throttle stop to get it to idle so I can set the timing and then ill adjust the bliss, then ill put the throttle stop back to factory

Can't plug into it as its a mix of obd and obd2 but missing the obd2 port so need to get a new one to wire back in, the obd port doesnt have enough pins so need to see if its been de-pined but I dont think so

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Drained some oil out of it as I was worried it being overfilled was causing me issues, also switch to a different set of spark plugs, tipping they are fouled now as well so will clean them up when I get round to it

Turbo outlet piping is now less dodgy, still not amazing but it works

Switched to another of the ecus I have and now the turbo light on the dash lights up so perhaps I was using the wrong ecu

One I'm using now is meant to be from an N23WG RVR according to Amyama, Im hoping it matches my 440cc injectors

One I previously had plugged in could be from an N13W, N23W or N23WG but doesn't bring up the turbo light

Set my electronic timing light to 0degrees and got it to the 0 degree mark on the crank

Managed to get my cheap timing light to finally work (the light is shit on this) and set it to 5degrees (2nd mark above the crank pulley) and it sounds so much happier
https://www.ebay.com.au/itm/Inductive-Pickup-New-Timing-Light-Ignition-with-Bright-Xenon-Strobe-Auto-Tool/273800803632?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649


Still need to check it again but it seems ok for now still loud but not as bad, no smoke in the exhaust and doesn't bang/pop. Need to set the Bliss and throttle stop screw as well but as I have a small leak in my lower rad hose join when its under pressure 90degrees I need to get the new T bolt clamps onto it once it cools down, the brand new coolant I put into it is also looking terrible so I think I need to flush the cooling system with the garden hose if I am take the lower rad hose off anyway. May have been some shit in the heater core etc, hoping this means the water pump is working however, and I know ill need to bleed air out

Need to also sort the below in no specific order

• Small gearbox oil leak (think its the seal for the cv on the drivers side)
• Reinstall oil temp gauge sensor in the Head as it wasn't reading anything where I had it (pressure was fine though) might also be a dead sensor
• check rad fan turns on at 92C (had a leak so didnt get it that hot) might have to get a fan switch and wire it in
• Weld the other side of the flexi on my exhaust, finish checking for exhaust leaks
• Add more power steering fluid
• Might do another oil change as its already filthy (tipping the extra detergent in the diesel oil has helped clean it up a little)
• Finish tidying up the wiring

Will take a video of it running when I get it going next

Discovered it is OBD1 so if I can get the right equipment I can read the ecu but not going to bother, also have a full ODB1 and OBD2 hybrid dash loom that the later motel GSR's had (needs ground on the 1 OBD1 pin) to work with the OBD2 port but the RVR and EVO 4g63 ECUS don't work with OBD2 from my understanding so no point

Also tempted to just throw the Speedunio in but want it working on a factory ecu first

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Checked the factory Radiator fan Relay and found the wire that needs to be grounded to activate it. Traced it to the factory plug and have got it ready to wire to the Thermostatic switch 

Once the thermostatic switch and Rad hose adapter arrive I can finish that and add coolant.

Have taken it off the stands so hoping to take it for a wheel alignment next month.

Checked ground clearance and its about 80mm from the dump pipe and the passenger side temp inter-cooler piping is similar. 

So need to raise it 25mm or remake some pipes :s 

probably should do some more work in the boot as well.

bumper doesn't fit that well (yay fibreglass) so need to think about how I deal with that