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turbovan

SR-1600

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Hi fellas,

Thought it was about time I brought this thread over from the archives.

(Old thread)

Most of you in SDC will have seen me around the place.

Anyway onto the pics...

The before pics:

1600front.jpg

1600back.jpg

1600inside.jpg

1600engine.jpg

The new engine:

sr1.jpg

sr2.jpg

After cleaning:

sr3.jpg

The work begins:

newdat1.jpg

Engine out:

newdat2.jpg

newdat3.jpg

Test fitting the engine:

newdat4.jpg

newdat5.jpg

Reversed crossmember and steering link:

newdat6.jpg

$350 chinese intercooler (now only $150 on ebay):

newdat7.jpg

newdat8.jpg

newdat9.jpg

It fits pretty well:

newdat10.jpg

newdat11.jpg

SWR surge tank:

newdat12.jpg

New engine mounts and suspension bits:

newdat13.jpg

BMW 7 series V8 radiator:

newdat14.jpg

It fits pretty well:

newdat15.jpg

200B SSS booster and 280ZX master test fitted after massaging inner guard:

newdat16.jpg

Making new fuel lines:

newdat17.jpg

Fuel lines nearly done:

newdat18.jpg

Surge tank and pumps fitted:

newdat19.jpg

More bits and pieces from Nissan and PLMS:

newdat20.jpg

Modified water outlet to simplify radiator plumbing:

newdat21.jpg

Modifying rear crossmember, first weld a piece inside the exisitng hole to center the hole saw on, then cut:

newdat22.jpg

The piece cut out:

newdat23.jpg

4" exhaust pipe offcut from exhaust shop:

newdat24.jpg

Welded in:

newdat25.jpg

Mount will have to be rejigged:

newdat26.jpg

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Radiator mounts:

newdat27.jpg

Radiator brand is "Nissens" 8)

newdat28.jpg

New brake lines made up:

newdat29.jpg

This saw loves to munch:

newdat30.jpg

Front of exhaust and cat:

newdat31.jpg

Rear of exhaust:

newdat32.jpg

Just tack welded together so far, still needs to be finished off.

R31 rears installed:

newdat33.jpg

TIG locker :

newdat34.jpg

Front struts are in:

newdat35.jpg

Exhaust tip:

newdat36.jpg

Heater pipes:

newdat37.jpg

newdat38.jpg

All fits behind grille:

newdat39.jpg

Still can be seen a bit:

newdat40.jpg

Engine bay is getting there now:

newdat41.jpg

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The car is basically finished now

Well stage 1 is finished anyway

Here's a quick report of how it went at Datnats (2005) :

After several very late nights, I got the car started on Thursday the day before we left. (Much thanks to PL's loom wizardry it started first go). Took it down to a mate's shop and did a quick wheel alignment then went to the dyno for a power run. It made 160kw on a conservative 11psi which I thought was OK for a stock engine, S14 turbo and stock ECU.

Drove it down to Goulburn on Friday, no dramas except a windscreen covered in oil when Simon Waterhouse's car dropped its oil everywhere in front of me.

The show day was pretty relaxing, checking out all the cars, there were a lot of nice ones there. I must have been asked about a hundred times what radiator and intercooler I had used.

Sunday was the track day with a hillclimb and regularity trial in the morning and supersprint in the afternoon. Was very pleased with the results at the track. Out of 100 cars I ended up 4th fastest outright in the supersprint, and fastest 1600 with a time of 1:13.07 (just beat Hayden Clark by 0.5 sec).

The 3 cars that were quicker were all dedicated track cars that were trailered there and had slicks, full roll cages, no interior, signage all over etc. (a Z32 with the works - think $100k++, Mark Alfords FJ20ET IPRA Sunny and a FJ20ET 120Y sports sedan).

It was fun to blast past a whole bunch of Z32 TT's, a few GTRs, RB powered Zeds etc.

I think with some suspension sorting I should be able to shave another 2 seconds at least off my best time.

Right at the end of the day, the oil pressure gauge sender T piece snapped off Bit of a downer but I have fixed it now with a braided hose to a remote manifold block. Will upload some pics of that soon.

Had an awesome weekend, really made it all worthwhile.

Here are a few more pics:

newdat44.jpg

A couple of sequence shots from zac510:

newdat45.jpg

newdat46.jpg

newdat47.jpg

newdat48.jpg

newdat49.jpg

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nice build mate, eveything has a purpose, absolutly no rice what so ever, and fast around the corners as well in a straight line, always wondered if those cheaper coolers would do the job, but seeing them used on a few projects here they dont seem to harm the hp figures in anyway,

how does the smaller fan go for heating when your in traffic????

loving the new plates by the way

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got to be the fastest and neatest conversion ever!

can't wait for stage 2 Chris

Iggy, just incase you missed it

newdat49.jpg

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Cheers fellas

Hoping to get onto stage 2 with some more upgrades later in the year

how does the smaller fan go for heating when your in traffic????

No problems in traffic, even on a 40 degree day it doesn't get above 90 degrees. More to do with the cooling capacity of the radiator i think.

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Nice build there mate,

Just wondering what diff set up you have ????????/

You will need to do stage 2 to beat me around wakefield ,

But if you had an FJ, You would have to go to stage 5, Giggle Giggle

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Nice build there mate,

Just wondering what diff set up you have ????????/

You will need to do stage 2 to beat me around wakefield ,

But if you had an FJ, You would have to go to stage 5, Giggle Giggle

wont you have to beat shanes time ?????? cough FJ

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Hey mate

Sorry for late reply, just got back from a Japan trip

My intercooler has 3" outlets. I used 3"->2.5" silicon reducing elbows to match to the 2.5" piping. Now I think you can buy the same cooler with 2.5" outlets which would make it a bit easier.

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Have clocked up 100,000 kms as daily driver since conversion with no real issues.

More upgrades have been:

A set of old school Recaros have been fitted

CV shafts from SWR and also Z32 brakes on the front.

Here are some shots of stereo install:

stereo1.jpg

stereo2.jpg

stereo3.jpg

You can see Audison LRx4.1k amp, Morel Ultimo 12" Sub and also the crossovers for the Hertz MLK 165 splits in the front. The andersen plug is so that the sub box can be removed for track days to save about 30kg :)

I made a new board from plywood (standard one is too flimsy) and riveted the standard plastic fuel tank cover panel to it.

And here are a couple from last datnats:

datnats111.jpg

datnats112.jpg

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Oil cooler install with ducting:

_cooler1.jpg

_cooler1a.jpg

_cooler2.jpg

_cooler3.jpg

Some photos of the final setup:

_complete1.jpg

_complete2.jpg

_complete3.jpg

_complete4.jpg

_complete5.jpg

Having a slight issue with the Z32 AFM - turbulence causing high airflow reading when dropping back to idle. This makes it too rich and wants to stall etc until the idle stabilises. With the minimum space available it is hard to maintain laminar flow through the AFM at very low flow levels. Will have to muck around a bit and see whether I can improve that.

Got it tuned last night and very pleased with the results.

The objective here was to make more power with the best possible repsonse (lowest boost threshold).

All the effort has paid off with a healthy 276 rwkw and a very fat power curve.

making 20psi boost at only 3000rpm and 25psi at 3400rpm dropping back to about 23 psi at max power

Here is a scan of the dyno curve:

_gt30dyno.jpg

Complete engine specs are now:

S13 SR20DET

Tomei 256 Poncams

GT3071R 0.78 split pulse rear housing

Twin Tial 48mm gates

Nismo 740cc injectors

Z32 AFM

Blitz EBC-II

Moroso Winged Sump

Oil Cooler

The rest is stock

I ran it on the dyno first with stock cams and then again with poncams - made about 40kw improvement.

Next stage at some point in the future will be Motec and Flex fuel so no need for AFM :-) but this setup will do for now.

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Only way to fix the idle issue is to move the AFM way forebears. Might just work with one of the apexi mushroom filters in the corner.

Or cut o hole in the guard...

Or have a go with an r35 AFM. Apparently the are stable quite close to the turbo

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So you had the same idle issues?

I would like to change to motec or autronic and add a flex fuel sensor to go E85 as next step so not overly concerned at this stage.

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I did with rb25 mad when I had it. Sorted it before the z32 went on.

But recently tuned a 'cough' Gemini with an sr same turbo as you same spot and the only way to fix it was to have the AFM right up on the corner with a bit of stocking as a filter. Haven't made a proper fix for it yet.

AFRs drop to 9's when you pull up

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Nice work there Chris, Love the power it has now,

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