Autocross Build: Evo 3

[Sirnixalot]

Painted the o2 housing with some VHT paint and wrapped the dump tube where it goes near the hot pipe


Installed


The catch can installed. I need to cut out some more from the bonnet where the vent is.


Fiberglassing the new gauge area. Needs body filler and some holes

My brother helped me out today, got the brakes and clutch bled, filled the transfer with Valvoline synthetic 85w140 and the transmission with 80w90 of the same brand

[Sirnixalot]

I got everything buttoned up today! #Took the dash back out so I can reinstall the new to me harness tomorrow.


Modified evo 9 actuator thanks AJ


engine bay shot


downpipe and dump tube


the custom turned solid crossmember bushings


no alternator!


limegreen!



mounted the twin fire up under the dash with some stainless plate

[Sirnixalot]

Evo pictures by Sirnixalot - Photobucket

awwwwwwwwwwwwwwwwww yeeeeeeeeeeeaaaaaaaaaaaaahhhhhhhhhhhhhhhh

[Lofty]

:h ellyeah::a pplause:

Wow. Awesome. Sounds mean! Looks great! NICE WORK DUDE!

Love the car.

[Sirnixalot]

Thanks

Kinda sucks that i couldn't get it finished during the week so i could re-license and re-insure it. I can't drive it without a steering wheel and open down pipe anyway.

The oil pressure is still kinda high at idle though 65-70psi and that's with the OFH already ported some. After its broken in i will buy some more OFH gaskets and get to dremeling it some more.

The rest of the exhaust is just waiting for some cuts and welding, a 2ft long louvered resonator (i can give up the 5hp for some noise control) and a large Magnaflow rear muffler so it should sound quite deep when its finished.

you have no idea! lol

It already looks like i have to take out the throttle body and do some more filing on the throttle blade as it isn't closing all the way (lowest tps percentage i can get is 10%).

Blipping the throttle the car comes out of vacuum quick. I don't think lag will be an issue at all

Just idling the water temps are pretty solid at 190-195 which i am happy with. We will see what they are at speed etc later.


Starting mileage


My new gauge area


What a difference this resonator made!

http://smg.photobucket.com/albums/v4...t=45cc27be.mp4
Link to another idling vid with the resonator on

[clipto]

Hey I wanted to know how that jayracing alternater relocation kit is working out for you.I am thinking of getting it clean up the front engine bay.Your car looks good man, keep it up.

[Sirnixalot]

It's working out great. It took a minute to figure out where everything went but its kinda self explanatory when you get everything out of the box.

The fuel pump failed so i borrowed one of those and the car goes like stink!

I have a small leak on the OFH (one of the oil cooler fittings) and regap the plugs then its ready for some logging.

[Sirnixalot]

So for some odd reason my car eats walbro's.

I put back in my stock pump and all is well. 12psi to the world!

Open dump wastegates are so freakin cool. I wasn't sold on the idea before but i sure as **** am now. NO spike, 12psi solid as a rock.



Finished the exhaust but i still have a leak up front somewhere that i think may be the V bands. Need to tighten them up and check the O2 to turbo bolts haven't loosened. The car is MUCH quieter now but that is still relative because of the leak. Once i get the car up on a lift i will drop the exhaust and paint the welds with the DEI header paint i have


Tomorrow it gets a wash!

[HaveBlue83]

i have a megain recirc O2.....it wont stay at 15 very long on the E316g. I set it for 20 and thought all was well but the cold weather and me continuing to tune it is making it spike to 25 sometimes.

I don't wanna do a dump as it's loud and a LOTTA hot air that can melt/burn things in the engine bay.

How do you like the different sound when WOT and fully spooled? I can swap mine out if this spiking doesnt stop.

build is getting along well man!

[Sirnixalot]

When I had the stock turbo on with an eBay recirc it was 25psi, no less lol.

The noise is....mean. It shouldn't bother you too much on the street if the boost is set at 15psi. I can see it getting old but I can also see its use for scaring tourists jay walking.

[Sirnixalot]

I love this combination!

2.3l + short runner exhaust manifold + exo X 20g turbo = instaboost!

I still have a few minor things to sort out and once I do the first oil hange this weekend I will post up some vdr results!

[Sirnixalot]

So after chasing a fuel supply issue for a few weeks, which ended up being a blocked solid Summit small fuel filter which i do not recommend at this point.

I have installed 4 new 4ga grounds throughout the car and did new 10ga wires to the fuel pump. I decided to swap out a known working stock Evo 7 pump which didn't change a thing so i knew my brand new Aeromotive was good, yahay!

I pull the element out of the filter and i cannot see light through it, some carb cleaner and compressed air later and everything is good.

I go to start the car on the evo 7 pump and all is well with the fuel pressure, so i rev the car a bit and hear knocking..........f*ck. So i take it out and put back in my Aeromotive, go to start the car and i go to start the car to get it home and out of my friends yard and nope...its locked up tighter than a nuns kitten.

This is what i get for buying a used 2.3L short block with a cut crank and stock rods (which i ended up having to sell the block since it had scores in one cylinder and then get new rings and bearings).

Plan is to take a stock JDM Evo 8 crank (not that it matters JDM or whatever) from another friend of mine and order up Wiseco 10.5:1 HD's , Manley H beams, new bearings and a Fuelab filter (many thanks to my wife for putting up with me and it). I also have an HKS 280 exhaust cam coming.

Tear down starts friday after work and continues all weekend. Monday i get the stuff and should at least have the bottom end assembled and then next weekend back on the road fingers crossed.

The up side is all my fuel system wiring is tip top, all my grounds are excessive, my fuel issue is solved and i will get to compare a 2.3L 8.5:1CR setup to a 2.0L 10.5:1 setup on this Evo X turbo.

Later on i will order some MAP stock Evo 8/9 replacement Beehive springs so i can raise the rev limit to 8250-8500.

[HaveBlue83]

wait......whaaaaaaaaaaaat?!?!?!

wow. FTL man....FTL....this angers me. I liked your updates. now you have to reverse and redo it again. im upset

[Sirnixalot]

Yeah it definitely sucks. I got a new to me JDM Evo 8 crank last night and i got the car towed back to my moms house tonight (where my work area and tools are). Tomorrow evening i am picking up a cherry picker and borrowing an engine stand since a buddy is borrowing mine.


What sucks even worse is that Wiseco's math does not add up as far as the compression ratio on those 10.5:1 HD's....they come in at 9.5:1 by all accounts, especially as the same pistons yields 10:1 in the later Evo's

85.5mm bore
88mm stroke
1.3mm head gasket
-4.5cc dish
47cc combustion chamber
0 deck clearance

comes out to 9.5:1

Anyways, it's probably for the best since i will be tuning on 93oct but they shouldn't advertise them as 10.5:1 as i would have bought JE's 10:1's instead.

I will post up tear down pics etc.

[HaveBlue83]

poop sandwich. yeah false adv.

damn i wish i could do all that computing. i just buy what they say it will work out to be. i will look into what it will ACTUALLY be now.

[Sirnixalot]

i found this site helpful for doing just that

Engine Compression Ratio (CR) Calculator

[Sirnixalot]

Welp my parts arrived and i got the motor out. I still need to pull the timing pulleys and head studs out. I will do that tomorrow on lunch and deliver the block to the machinist with the pistons and hopefully the clearance will still be in spec after the light hone.


Evo 8 280* 10.2mm lift exhaust cam installed. I am locating a stock evo 8 cam gear so i can badger one of my stock ones and drill the later evo hole then transfer that hole to my HKS cam gears so that i won't have to physically count the 10 teeth and just time everything up normally. I really need to get a set of MAP Evo 8 replacement valve springs at some point.


The new push lock oil drain, if only the hose were black sigh


Oil cooler thermostats, the shiny one is HKS and the dull one is the Evo 8 OEM one


Installed


Wiseco flat tops! I figured out how they get their 10.5:1 advertised CR. When used in the 4g64 block with the dsm 4g63 head they are 10.5:1. As a drop in for the later Evo's they are 10:1 and in the DSM/my application they are 9.5:1.

[bad2g6bolt]

Nice fab work, cool build.

[HaveBlue83]

there we go! progress!

[dsmdeliveryboy]

Awesome build thread, so sad to hear about your engine but it sounds like you've figured out something even better and your on the right track!

[Sirnixalot]

Well i got it up and running It definitely needs a retune though.

I managed to leave the RTV too long to set up on the oil pan so i have a small leak from the front of the pan and i tore an axle boot. The shop i used to work at has the car and is gonna take care of that for me tomorrow since i really don't have any time this week to get under the car (read i am being lazy)

I should be doing some idle fuel trim logs tomorrow after work and MAYBE some cruising logs for the mid trims.

I know its not the best vid but here is more proof that the Evo 8 cams can be made to work in our head. I am running an Evo 3/DSM HKS 272* intake and an Evo 8 280* exhaust cam.(if you consider a video that is basically darkness with one head light on and a car idling on the word of a complete stranger proof)


If you have cam gears that have the dowel holes for both the DSM and Evo applications then its even easier. I just rotated the inner hub of my cam gear to point the Evo 8 cam dowel to the front of the car which left the cam timing marks alone to make things easier to time up. (Evo 8 dowels point out and DSM dowels point up)

The car is definitely lacking some low end and it is a little "laggy". 2.3L spoiled me for sure.

Look for autocross vids end of month!

*EDIT*
MUCH better vid of the sound at idle (1200rpm need to work on that and get it down to at least 1000rpm)





Idling temps The AFCO scirocco rad, twin 750cfm fans and Ralliart thermostat (160*F) are working nicely. The oil cooler thermostat is a 71*C unit from HKS so all appears to be well on the idling front. I will report back after some logging 3rd gear pulls.

The Apexi gauge is in *C (oil) and the Summit red LED gauge is in *F (coolant)

[907dsm]

Car sounds good man, glad to see you got it back up and running man. I love the accent man, my family is from St.Croix and all other parts of the virgin islands haha.

[Sirnixalot]

Thanks...how the hell unna end up in Alaska?! Miami gets too cold to us at times much less up so!

I am having a minor issue preventing me from really starting to tune the car. The damned low fuel trims aren't logging.

I have tried swapping to a different rom, double checking all the periphery settings but still no joy. I will be doing a long cruise session this week to see if that gets them to show up!

I have knocked down the timing around 2000-3000rpm in the 70-120 load areas which has cured my knock. The car goes like stink on 10psi on this "tune" I have been taking it relatively easy since i still only have 100 miles on the new motor, i did seat the rings with lots of engine braking and some boost up to like 4000rpm, but was afraid to spin bearings again so i have not really used the whole rev range.

I should hopefully get some logs and virtual dyno stuff up this week.

[Sirnixalot]

No such luck! Been busy all week sorting out little gremlins.

This weekend i am building a battery tray for behind the passenger seat and the seal for the fuel pump hanger that goes around the plug for the wiring is leaking so i need to take the hanger out and seal that up with something.

Hopefully i get to do the cruising logs this weekend to reset the fuel trims so i can get onto some WOT tuning

[Sirnixalot]

Still a work in progress but

The red lines are where i am at now on 14psi and the green line is were i was at before i tore into the car at 25psi.

I will be more than fine with the 14psi tune for autocross. After this months event i will crank up to 22psi and do some more logging.

[Sirnixalot]

So over the weekend i got to my first autocross event to shake the car down.

The first 2 runs were plagued with a fuel cut problem which turned out being a loose connection on the fuel pump relay (would disconnect on left turns, probably karma for making fun of nascar).

I fixed that and then ended up over driving and getting in a fight with a 4x4 post real estate sign





I have already found a replacement hood and getting a new fender this week. The bumper needs some heat gun and filler treatment.

The head light i will leave out for now.

Some better pics from the day lol

[mattasi]

Well at least you were having fun with the car before hitting the pole. .

When your motor went out and started knocking you put together a new motor. Did you rebuild the turbo? Just curious, some do, some don't. because of the metal chips and what not.

[Sirnixalot]

Nah I didn't rebuild the turbo. I plan on inspecting the the turbo for shaft play when i replace the front body panels this weekend though.

So far it has been doing just fine

[Sirnixalot]

Well i got the body work done at the local Ford dealer (best body shop on the rock {thumbup} ) and i gave the car a single coat (need to do another of semigloss rattle can!

It needs another coat and thin layer of filler over the holes i welded up on the trunk lid.








Tomorrow i should be getting a 3.5bar map sensor so i can start playing with ecu controlled boost (its at 10psi right now). Going to go for 18psi and see what we get.

[HaveBlue83]

yay back at it again! good stuff buddy