otoshare: ae92 4agte build New Zealand

hi all, ive been on the forums for a while now but havent posted much in the last few years. i though ill post up my build for you guys (copied it mostly from another forum which i post regularly on)

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heres my soon to be finished (hopefully) 4agte ae92 fxgt

or originally going to be a ae92 sedan but a learner driver with out a supervisor, wof, reg or insurance that decided to not give way made sure that did happen.

specs:

blacktop 4age block

4agze 8.9:1 oversized pistons and rods

550cc 3sgte injectors

action dan manifold

bazda supplied turbo

tial 38mm wastegate

tial copy 50mm bov (will get original when i get some more $$)

Link LEM G3 ecu

3" stainless exhaust

2.5" stainless IC piping

600x280x76 DSR intercooler

E58 gearbox with some sort of mechanical LSD

old engine

semi clean engine bay (20 years of road dirt and grime to clean)

shot of the mess ive made in the once clean and organized garage

head and rods waiting to be picked up to get built

engine back from being built by camb01 (thanks cam)

gearbox getting some new synchro (thanks warrick for sorting them out for me)

dirty corroded gearbox

after cleaning and sanding for a night the gearbox looks shiny again

engine headding back into its new home

intercooler position mockup

engine bay

car is now back in the garage so that i can work on it when its raining and work late into the night.

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computer is all wired up now and just need to setup the link before it can start.

been working on making the aluminum half size radiator fit. had to remove the old bottom radiator mount and hack some of the side pannel off, then cut the outlet off so that it wouldnt hit the engine mount. just need to find someone to weld up the hole and make a new outlet and make up some brackets to hold it all in place.

old

new hacked area

fitment (almost looks stock)

shouldnt have problems with cooling now.

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down pipe half done

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been finishing up the exhaust for the past week and finally got it all done today

not bad for my first exhaust system and first time welding anything other than bits of scrap metal together. heres come close ups of some of the welds

ended up using a big fart cannon because i couldnt find a low key looking muffler that would fit for a decent price. got this one for 35 and its a genuine rsr one in pretty good condition considering its off a honda.

also got the intake plenum back from the powder coaters as well

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finished up the intercooler piping today and relocated the battery into the boot, bov and air intake temp sensor welded on. not too much more to go.

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mounted oil cooler behind grill and also mounted the radiator fan.

also it lives now

VIDEO

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all finished now and getting tuned, as it was getting tuned turned out the cas was sending out bung signals and clutch is slipping at

Reply 1 : ae92 4agte build New Zealand

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new brackets

the outer fins on the caliper hit the inside face of the spokes so i will need to mill them off then just need to get some new lines made up

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on the way home after passing some cops doing some speed checks with the laser gun and pulling people over, i get past the commotion and think to my self "hahhahaha suckers that what u get for speeding". i get to an t intersection. it was green so so i carry on then a car runs a red light and slams into my door.

it wasnt her car, she had no insurance or a license.

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got a new car to plonk the turbo engine

old engine out

16v small port from the gti

removed the battery tray

modified the radiator supports and some sports of rust and managed to get the engine before i packed up tonight

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the finished product;

managed to finish in time for the drags. only managed a 13.9 due to the lack of traction and slow ass reaction times. was a good learning experience and should be better next time round

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went to the drags on the 27th with some better tires and managed a 13.40s 1/4 mile. still no traction in 1st so my 60ft times are still pretty average. tried taking off in second gear but it just stalled on the start line or bogged. so next time ill get some full drag slicks and see how that goes.

http://www.youtube.com/watch?v=WpgcizLDuE8

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my late Christmas present to my self;

a set of 800cc SARD injectors, got them for $225 each which is quite reasonable and considering the price of parts is expected to go up due to the dollar i think it was a wise decision to buy them now. Also it means that buy the next drag meet i will have more power to play with since im going in for a tune next week.

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New power figures on 22psi of boost

next is to save up a bit more for race gas and go for more boost.

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got tuned on Q16 fuel (similar to C16, slightly more stable on higher boost)

340kw on 29psi

365kw on 32psi

unfortunately turbo compressor went pop and disentigrated damaging the backing part of the compressor housing. so time for a new turbo and stick to 29psi.

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graphs of latest tune

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on a side note from all the recent destruction, I've converted to evo coil packs and igniter and it has performed flawlessly.

pieces removed from intake system. pile on the right is from the intercooler piping straight after turbo and pile on left is what was in the entry tank of the intercooler. after intercooler there was pretty much nothing left.

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cars all back together now and took it for a "test" run. now spins up in third on the motorway and is just too fast to be on the streets for any sane person (only running 29psi btw). the "test" run really highlighted the inadequate brakes and suspension i have it sor of floats around when boost comes on.

when i was putting the silicon joiner back on i noticed some bits of the compressor embedded into the joiner, and also one piece managed to punch a hole right through the joiner.

also heres a wee vid of the car i just took http://www.youtube.com/watch?v=H_kYrjtLAJc

Reply 2 : ae92 4agte build New Zealand

Nice!!!

Those are the 4agze pistons and rods holding up to 29psi???

Reply 3 : ae92 4agte build New Zealand

Sweet build... I love the AE92 FX, wish they had brought it to North America.

Reply 4 : ae92 4agte build New Zealand

so how did your turbo fail ?

Reply 5 : ae92 4agte build New Zealand

stock pistons and rods are holding up fine, and as to the turbo failure there are different theories. one is that the nut became loose allowing the comp wheel to move around and contact the wall shattering. another is that it just reached it mechanical limits with a small piece coming off or cracking making the whole thing unbalanced, at those high rpm its will just self destruct if its unbalanced.

Reply 6 : ae92 4agte build New Zealand

some updates to the car

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Originally Posted by gasman

went to the drags today and bought my full slicks allong and they picked up on them and told me if i ran them i get the boot.

so i had to run my road tyres. first run i still had the silencer plugged in the muffler and tires fully inflated. the time slip says i got a 12.4 but i wouldn't trust it since it also says my 60ft was zero.

second run i prepped my car a bit better and got a 12.9

Vid

third run the turbo crapped out during either the burnout or the launch and ran at 16sec 1/4 in na form.

Vid

pics of the damage.

and the end result for the drive home:

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Originally Posted by gasman

got a new turbo, a Masterpower T58; same one as bazda.

also plumbed back the wastegate so i could get a cert and wof

i couldnt fine one of those small flexi's so bought a 200mm long one and chopped it down, looks a lot cleaner IMO but it was a bitch to weld, heres some pics of me dissecting the flexi

cut off the end sleves

cut the outer braiding off below the spot welds

pulling off the brading

and cutting off a smaller section

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Originally Posted by gasman

new tune with new turbo and new plenum. basically the same as it was but with less broken turbos.

Results:

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Originally Posted by gasman

bit of an update.

went to the drags back in november but ended up eating my gearbox and clutch started to slip in 4th gear on the 358kw tune.

managed a 13.3 and a 122mph trap speed on semi slicks.

after towing it back home it sat in my driveway untill mid jan of this year when i pulled off the box and clutch.

heres what i found:

the kevlar side is just down to the rivets but the ceramic side still has some meat left.

one slightly cooked and gauged pressureplate

one mildly cooked flywheel but no gauging.

so i pulled it all off and got the clutch plate rebuilt with ceramic pucks on both sides and reinstalled it

as for the gearbox im going to be running a aw11 box with a mechanical lsd.

heres some pictures of the conversion process to make it work with a ae92 shifter. it uses my old shifter assembly and to make that work i had to blank off the old shaft hole with a 28mm frost plug and drilled and tapped two new holes for the shifter linkage.

with my old gearbox i cleaned it up using a wire brush, wet dry sand paper and a whole heap of elbow grease this time around i went in search of some hydrofloric acid to chemically clean it but couldnt find any.

while searching for the acid i came allong some oven cleaner and since it says do no use on aluminum it must mean that it eats into it which is just what i need so i bought that and sprayed it all over the gearbox let it sit for a while and washed it off.

it worked well with the thinner corrosion and heavy corrosion just required a second application allong with a light scrub.

with the gearbox reinstalled i also reconfigured some plumbing and fixed up some wiring and also welded in a new bracket to mount my honda city overflow onto the chassis side rail under the airfilter. the overflow was previously cable tied to some hole over by the wiper motor.

nex on the to do is a cert for some BC coil overs i installed, then i can be legal once again.

Reply 7 : ae92 4agte build New Zealand

That's insane!!! It's putting out some VERY respectable figures. Sorry to hear about your white Corolla, good to see that you kept soldiering on though. Your car is a true inspiration. Lookin' forward to seeing a video one day

Reply 8 : ae92 4agte build New Zealand

Wow!!!

If I am reading those dyno charts right, it is puting out 2008 Nm, and 385 kW.

From the conversion charts I have found, that converts to 1480 ft/lb and 516 hp.

THAT IS INSANE!!!

WOW!!!

I am impressed.

Reply 9 : ae92 4agte build New Zealand

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Originally Posted by Kiwi-Corolla
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theres a couple of video under my youtube account name "justinsue"

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Originally Posted by Donald
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Wow!!!

If I am reading those dyno charts right, it is puting out 2008 Nm, and 385 kW.

From the conversion charts I have found, that converts to 1480 ft/lb and 516 hp.

THAT IS INSANE!!!

WOW!!!

I am impressed.

that torque figure is measured torque at the wheels so divide that byt the final drive and 4th gear ratio of a e58 gtz box and you will have the torque at the flywheel

Reply 10 : ae92 4agte build New Zealand

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Originally Posted by gasman
View Post

that torque figure is measured torque at the wheels so divide that byt the final drive and 4th gear ratio of a e58 gtz box and you will have the torque at the flywheel

Ok. But that is still over 300ft/lb (I think).

I still say WOW!

I think I need to slap a turbo on my 7A-FE.

Reply 11 : ae92 4agte build New Zealand

I just noticed that you have it for sale on TradeMe!

. Hope it goes to a really good home.

Reply 12 : ae92 4agte build New Zealand

when ya did the LN130 calipers, did you just use standard size 90 series discs? how hard to do those brackets too? get them CNC cut? i was lookin at doing the same thing myself, mainly to fill in the wheels rather than stopping power. f**kin' sweet car bro, doin Kiwis proud. any help would be awesome, i would have given it a new home if i had the cash =(

Reply 13 : ae92 4agte build New Zealand

"Do not use on aluminium"

*uses on aluminium*

That's the spirit!

otoshare

Friday, March 25, 2011

ae92 4agte build New Zealand

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