Lush's dohc 4g63 sigma wagon

[lush]

A couple years late with this build thread but here it is for the internet 

I've known of this wagon for over 15 years and managed to buy it 3 years ago as a rolling body in bits.

I knew it was tidy for an old sigma so pulled trigger on buying it.

I dropped a dohc 6 bolt 4g63 in fairly instantly then didn't touch it for a very long time

My first attempt at a waterline that was ugly as can be 

I binned it 

 

 

[lush]

I modified the intake manifold to suit being rwd as obviously it was a fwd motor

But I wasn't happy with it at all

I wanted the motor to look as factory as possible like it belongs there

So an Evo 4 intake manifold was test fitted

The bolt holes are the same but there was difference as it's smallport vs motor is bigport 

And more importantly the Evo 4 intake has injector holes on manifold vs head has injector holes in head. 

But it definitely looks better so the decision was made

Keep the 6 bolt galant bottom end but ditch the head and go to an rvr 7 bolt head that I have spare

Reasons behind this decision were

*Smallport so intake works

* Cam sensor is on cam gear not back of head 

* I've always grown up with the yarn of smallport head was better on vr4 bottom end so yeah

This requires drilling the head stud holes out to suit vr4 size head studs as 7 bolt run a smaller head stud to 6 bolt. 

Luckily a local shop did a trade deal for some vr4 parts they needed for my head work to be done. 

 

[lush]

The yummy stuff all you pests love

I'm too impatient to weld panel steel but I found the culprit 

Dudley / daif / shaggy 

Whatever you wanna call this specimen just don't use his real name 

Does a good job that's for sure 

[lush]

More rust work 

This also had no rear bumper and I searched a long time with no success to find a chrome sigma bumper

Soooo ke70 wagon bumper was modded to fit and not that bad fit

  

And a new old stock guard was found 

[lush]

The first intake I made

That got replaced with the Evo 4 intake after welding up injector holes and reshaping to suit

Looks heaps better in my eyes

[lush]

7 bolt rvr turbo 4g63t with crank and cam sensors 

 

Unfortunately the front cover/ oil pump etc on a 7 bolt is different to 6 bolt so wasn't able to use crank sensor sooooo

I made my own mount for crank sensor using cardboard cad design. after consultation with the big dawg @kpr he release the secret sauce recipe because I pose no threat to his client base of 4age enthusiasts 

 

Some adjustments were made to the original design but we got there with a slight shave of the front cover 

 

[lush]

[lush]

[lush]

The temptations to just go sohc turbo 4g63t dwindled on me alot 

A 4g61t (1600cc of fury) went to the chopping block, this one had 50psi  across all cylinders 

It sacrificed its front cover and oil pump to the greater cause

For those unaware the 4g61t had no balance shafts and a short oil pump stub. So essentially a balance shaft delete kit for the 4g63

The rvr 4g63 head arrived back from engine shop

Painted the block , new frost bungs, new water pump (rwd/sohc slightly shaved for dohc)

 

[lush]

Found pics of the car the 4g61t motor came from

It's glory days

And how I found it....

[lush]

Gave the wiring stuff a go. Got as far as labelling all inputs/ outputs then got scared and requested some supervision from karl before proceeding any further 

Found some 15x7/8 pine mo1 wheels still as new for a fraction of their price tag ( don't dollar reserve) 

Eclat just absolutely stoked to be handling such cool NZ made wheels 

And I hate munters that cut doorcards for speakers....

So I splashed out on some tidy second hand ones 

[lush]

This took more then one attempt 

My impatience got the better of me and I just mig welded it 

I'll do better next time....

Maybe

[lush]

15x7 0p 175/50

15x8 20p 195/45

Trying to inspire the boys at work to make better wheel choices 

[lush]

Next was exhaust mods

Some extractors from @bigfoot had to use what bits I had to join to my existing exhaust

 

[lush]

The absolute legend himself karl @82Mirage made the hike down from the far north to do my wiring.

So I'm running a link g3 with the  garage4G crank sensor kit, factory rvr cam sensor but we had to modify the pickup wheel. It had two tooth so I cut one off to give it just one. 

 

It was a sad day for Karl's footwear of choice. r.i.p. jandal

 

[lush]

Some of my finest work 

 

Also front end assemble and touchdown 

[lush]

First start up had only minor issues 

A water leak, easy fix

A vacuum line I ran wrong 

Throttle body needed a blank plate for idle control valve as above 

The mission to get it out of the shed 

And @82Mirage back at it making adjustments to the base map. 

[lush]

Next was a wheel alignment, thanks to the bro eclat again 

 

And then off to none other then Krispy Kreme @kpr

140 horse ponies which I believe is equivalent to 62,375 ducks 

And a quick test drive out the coast afterwards. The feeling was unreal 

This car has been off the road since 2013

[Dudley]

No damages to car trailer guards getting it to criskscuzzytunes?

[lush]

Really been thrown in it here, so as the tales of the town would have it. 

Someone may have ran over their trailer guard unloading a vehicle of similar description, and not only that but the exhaust caught the driveway and bent itself 

But these are only tales as we know the rules be layed in cement 

Pics or didn't happen.....