Popular Post Bananaman Posted June 16, 2020 Popular Post Share Posted June 16, 2020 Link to discussion thread Thought I might share this with the oldschool community. I did attempt to attend an old school track day in Taupo right back at the start when I brought this car but had a shattered wind screen in Waiouru which prevented me from attending. So quick run down. Car is a 73 Ke20 2 door sedan which was aussie built. Check out the youtube clip of the cars first build below. SR20DET, roll cage, paint was all completed in Australia. Since I brought it I have overhauled most of the car, had some fun but now it is time for my version two with reliability in mind. Will start this with progress pics to date and take it from there. Original Build video https://www.youtube.com/watch?v=h35kYINEhaw From the drive home. This is how I brought it. First show. Now the strip and rebuild Stripped every bit of wiring from the car, all panels from doors forward removed. I have taken the entire fuel system out and will focus on the wiring aspect first then for a mix of all things to finish it the way I wanted. 22 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted June 17, 2020 Author Popular Post Share Posted June 17, 2020 And so the journey begins, I have gathered most of the supplies I need to get on and do the wiring job, bearing in mind I have no automotive electrical back round or experience this should be entertaining. My experience only extends as far as fitting audio systems. So step 1, complete the High Performance Academy club level wiring course online. (I recommend this to anyone wanting to know more about the fundamentals of EFI wiring. Still a few blanks as they don't delve deep enough into other wiring systems that are basic functions in most cars. Luckily I have VERY basic needs. Not too many electronics in the old boy. Materials. Will be dealing with all the lights on the car and upgrading them to LED to help with power distribution as the car has ALWAYS suffered from electrical gremlins. So I began right at the back rebuilding the rear light holder with new wiring and lights. Still waiting on a shipment of DR25 before I can terminate the lights at present but that shouldn't be too long. Factory vs rebuild 14 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted July 2, 2020 Author Share Posted July 2, 2020 So not much to see here but I did manage to get all the supplies I need to complete my test wiring of the tail lights. So here is one of the finished light holders. Learned all the pitfalls of using this wire / plug / sheathing which is good because I don't want to make any mistakes on the balance of the car wiring. 7 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted July 26, 2020 Author Share Posted July 26, 2020 So made a wee bit more progress. Unfortunately I don't get the time I would like on this build but still. So number plate lights out for a refresh and LED treatment. Look amazing attached to the bumper, once removed and stripped down it is a different story. Actually writing under there. Next up was the boot loom. Dealing with lighting only on this loom. Tail lights, numberplate lights, hi stop, and untilize the factory earth which wasn't being used when I stripped the car :/ All ready to be terminated. 8 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted August 31, 2020 Author Share Posted August 31, 2020 So not the most lush update but the rear wiring loom is in and the light quality is some much better. Wiring images up first. Jiffy plugs, these things are awesome. All terminated Installed. Light quality so good. Fuel catch tray, work in progress. 9 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted September 1, 2020 Author Popular Post Share Posted September 1, 2020 Got my label printer all sorted and some clear to go over the top. Wiring dreams coming true. That semi pro look hopefully, will be working on the front sections of wiring next. 12 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted September 17, 2020 Author Popular Post Share Posted September 17, 2020 So update time again so this doesnt go stale. Wiring mockup done. Took exception to the placement of the IAT sensor so have fixed that. Location couldnt be any better than this. Power distribution has also arrived so now the biggest hurdle is having time to put into this. Bulkhead connector should arrive tomorrow so I can start to get the engine harness finished. Really looking forward to see it done. 10 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted September 17, 2020 Author Popular Post Share Posted September 17, 2020 And today the bulkhead connector has arrived. So stoked to have this piece of gear. 11 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted September 25, 2020 Author Share Posted September 25, 2020 More wire stuff. So to make an omelette first you must break some eggs. So trials first, glad I did. I have just about completed the first section of the engine wiring. Feeling pumped. Also picked up some weld on AN fittings and top radiator return block from Taarks for the cooling system. More on this later. 5 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted October 12, 2020 Author Popular Post Share Posted October 12, 2020 Mixed bag for this update, some good along with some bad. Looks like the original signal switch was replaced with a repo one that has had full light current passed thru it at some point in its life. No wonder this car has suffered constantly with power issues. Have finished up most of the engine harness including the coil loom. Just waiting on a few last minute supplies for the engine harness to be terminated at the firewall, install the modified radiator and make hoses then out with the engine and gearbox 10 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted October 22, 2020 Author Share Posted October 22, 2020 Intentionally overlooking the update surrounding the -an conversion for the cooling system as I have struck a problem. I am currently looking at options to get the top hose to fit in the limited space I have available. Will update this aspect of the build once it is finalized and I actually have a solution.Focus recently has been to get the intake manifold sorted, it was a custom fabricated item that was on the car when I first purchased the car. Looks good but in practice it has some issues.Firstly, there is not a single boss welded on this manifold. Instead they opted to tap the 3mm alloy to attached the IAT, vacuum lines and throttle body. Will discuss one at a time.1/ IAT. As noted in the previous posts it was right at the back of the intake manifold on the underside, not an ideal spot so I have had a boss welded on my intercooler pipe right before the throttle body. Win. However this now leaves a hole in the intake manifold. Plan is to weld a boss on from EFI Solutions in Australia which will give me a series of vacuum lines so I can get that side of things sorted. Aiming to convert all vacuum lines to push-lok fittings to keep things easily maintained.2/ Existing vacuum lines, now that I have a new location tucked under the intake manifold for these to come out from I need to weld over the back of the intake manifold. It was a mess! Once parts arrive to weld on I will update with finished pics. For now this is what it looks like.3/ Throttle body. Now this has a number of more serious issues which have arisen over the few years I have had this car. Now that I have stripped it all down it is apparent where they come from. Firstly the mounting of the throttle body to the intake manifold. Again no Boss used, BUT the surface of the manifold is not even flat. It would seem they made the end plate for the intake to suit the throttle body then welded it on with no consideration of the weld lifting the throttle body itself. This has created a leak at the two lower bolt heads as seen in these pics.Not the end of the world. But I am having a new adaptor plate machined so that it can be welded on the intake and will also incorporate a o-ring seal between the adaptor and throttle body. Pics when it is made and on to follow.The more serious issues, the throttle butterfly could move almost 10° without the throttle being pressed. This resulted in the car revving upto 3500RPM when stopping at lights or even on deceleration it continued to rev. Not ideal.Turns out it was the cap screw on the right of this picture. The head has bottomed out on the throttle linkage and hasn't even threaded far enough to hold the shaft the butterfly attaches to. Fixed, proper fitting grub screw that is fully secure. Maximum satisfaction.Next was the TPS, it was also held on with cap screws that had a head too small to locate it where it was supposed to be. When the car was dyno'd the first time my tuner @ross discovered the problem where the TPS was bottoming out on the underside on the throttle body housing resulting in the tps staying a WOT. (clearly this leads to some excitement when you climb up the car then jump off the pedal only to find it isn't slowing at all) Correct hardware securely fixed and the problem is solved.Proper hardware for those two fixes owes me a grand total of around 0.35cents. Hard to believe you wouldnt fix those at the beginning.So once the boss parts arrive I will have them welded on and update intake progress. For now I have an engine crane on loan to remove the engine and gearbox ready for the engine bay overhaul. 9 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted December 6, 2020 Author Share Posted December 6, 2020 So bit of a better update for those following.Firstly, the exhaust manifold. Let me start by saying unlike just about every other build I have seen recently people seem to be chasing big HP numbers. That was never the intention of this build, I am trying to attempt to build a responsive fun daily car that I can throw around a track at a club day with mates. Not looking to win any races or smoke too many tires although it does a reasonable job of that at the moment.So the exhaust manifold. I picked up the Sinco manifold a few months ago since it was something on the list but lack of research has meant I have had to replace it with another. The one I brought was a T3 flange with a 45mm external wastegate. I really wanted to put a gen2 garrett turbo on however the smallest Gen2 T3 flange was a 3071 which I deemed to big for my application. Instead I wanted to put a more modest 2867 which meets my power goals with enough up its sleeve to keep me in the efficiency range of the turbo. This is where the manifold now longer suits. The 28 frame garrett only has a T2x flange or a 2.5" Vband to attach to the manifold. To add to the this if you opt for the T2 flange you have to run the internal wastegate. Since Sinco dont do a 2.5" Vband on there manifolds it meant to stick with Sinco I have had to stay with the T2 flange and internal wastegate. For ease of installation I have gone down this road. So, now that I had made up my mind I brought the turbo and figured a turbosmart actuator will give me reasonable boost control for my mild street build. Next on the list was to sort the intake manifold pictured above. The first step was put the IAT sensor into the intercooler pipe rather than at the back of the intake manifold. This was the original location, simply tapped the sensor into the 3mm aluminium. Punched holes were drilled out for the new vacuum boss.Then since I moved the vacuum lines to under the intake I had to do something about the horrid assortment of once again tapped holes in the end of the intake. (SAD FACE)After.And lastly the borage or issues that surrounded the throttle body. Mainly the fact that it didn't sit flush to the surface as mentioned in the post above with the other little issues. I had my good mate Shannon at PRO CNC Ltd knock me out a new flange complete with o'ring seal machined in.And another addition to my wiring tools I was stoked to get a nice new stop for my wire strippers. By eye is one thing, repeatable it awesome. 8 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted February 11, 2021 Author Share Posted February 11, 2021 Been intentionally putting off the radiator update until I had a clear solution to my space restriction problem. Now I have an idea it is full steam ahead before I pull the engine out. So plan is to make a fill pot like Nigels from ETS on his PS13. (pictured below) So I am gathering materials and will post some pictures up once I have it all welded up. Should look cool and be totally functional. Not much else happening with it just at the moment since I have other priorities but hoping to jump back into it soon enough. 7 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted March 3, 2021 Author Share Posted March 3, 2021 From concept to reality. Stoked to have picked this up today. Still have to drill some mounting holes and then polish it up but so happy with the final result. 7 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted March 23, 2021 Author Share Posted March 23, 2021 Sometimes taking a car back to a blank canvas is a good idea. In my case this is a great idea. From engine mounts that were finger tight to burnt out electrics I am happy to be at the turning point. Only dealing with paint in the engine bay and radiator support panel so it is off to the media blasters to strip it back very shortly. 6 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted March 29, 2021 Author Share Posted March 29, 2021 Some progress this weekend. (and some things I havent shared) Cardboard aided design to water cut and painted engine lift hooks. Had to install my bulkhead connections before I get the bay stripped and fix the fuckup that the previous owner has created with what looks like a sledge hammer #facepalm Before: After: 3 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted May 20, 2021 Author Popular Post Share Posted May 20, 2021 Posting more problems than solutions. But god damn who ever worked on this car prior to me needs a kick in the nuts! Tearing down the front end for sand blasting / powder coating which will also let me replace bushes and ball joints as I go. However it would be useful if the removable parts could actually be removed!! And how about reusing the dump pipe with my new turbo setup..... Nope, gas and a hammer seemed to make this one fit another chassis (there was no clearance issues in this car) But one thing has worked out. 15 Quote Link to comment Share on other sites More sharing options...
Bananaman Posted July 27, 2021 Author Share Posted July 27, 2021 So after the last round of ups and downs I have some fresh bits to add to the pile I call a car. Caster rods & mounts, bonnet hinges, engine mounts, tow hooks, gearbox x-member all looking great now Can remove the rimu x-member once the sandblasting and painting happens. But I do have a nice shiny front x-member now. And the most satisfying part fixing the LCA problems. New whiteline LCA bushes, ball joints and a freshen up. 9 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted October 12, 2021 Author Popular Post Share Posted October 12, 2021 Must be time for an update how ever small it might be. Been working on a few details and sourcing parts mainly. Firstly, I have to relocated the brake and clutch reservoirs from the top of the pedal box to a location that is easily accessible for filling and monitoring. So my first thought was I need to move my gauges so I can put them in behind the dash up high enough they will still gravity feed the pedal box. Enter my first mission, new custom centre console. Some CAD (cardboard aided design) first. The cut it open and did a proper cad template and transferred that to a piece of styrene. The styrene is easy to shape so a little heat and we had something that looked to work. So next step was to lay out the gauges and switches I wanted to have in there and send it to the local waterjet man to have it cut. Luckily I work at a company that does roofing so folding the final cut piece was easy. Now to template up the sides and mark out for the shifter to come thru. Once I have this piece constructed it is then time to pull the dash and begin modding it to what I want it to finally be. Also started to put the front end back together with all new hardware with a very close eye on tolerances to remove excessive play in the old boy. Final buttons and dash lights are on there way, have also acquired more crimp tools for the metri pack terminals so once I have all this in place I can mount the fuse box in behind the console which is also where I am going to mount the ECU. More of that to come later. 14 Quote Link to comment Share on other sites More sharing options...
Popular Post Bananaman Posted March 4, 2022 Author Popular Post Share Posted March 4, 2022 Been absent for a while so here is a small update for those following this. Been mostly body work for now, some suspension considerations and trying to piece together a sway bar that might fit my conversion as the factory one was removed in favor of getting the engine in which is not ideal. Before. During. After. About 10 hours per side which is crazy but getting there. Had problems sourcing transport to take it to the sand blasters so did underneath and the sides so I can start mocking up the suspension and sway bar. And rejuvenating all the old parts. Some I havent shown in this thread will do a proper update at final assembly. So now the mockup begins. KE70 vs KE30. Most likely go with the smaller KE30 bar as it fits the car will less problems. Will update after the weekend as I drop the engine back in to check sump clearance. 10 Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.