this will be my follow up thread to the worst summer ever (http://"http://www.foxtbirdcougarforums.com/showthread.php?t=25231") thread. its time to bring the car back to a normal level of performance after the summer of abuse as my DD.
the priority list:
- "new" turbo
- reconfigure exhaust
- new clutch
- rebuild IRS diff
the "if i have time" list:
- poly rear spring isolaters
- better rear shocks
- par down wiring harness
- dash swap
ive got some turbo stuff here now. i bought shawn's sc5031e hybrid. it was rebuilt ~6000miles ago.
i got a 3" v-band outlet to put on it, and was planning on running that till i read about a few guys on TF having boost creep issues with the sc50 and good flowing post-turbo exhausts.
instead of taking that chance, i bought a cosworth turbine housing to put on it. should help spool
and have better boost control.
cossie vs. .63 precision w/v-band outlet
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC170003.jpg)
other cossie housing pics
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC170002.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC170001.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC170005.jpg)
mocked up the housing to see what im gonna need to get the 3" DP connected
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC180005.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC180006.jpg)
the .63 precision housing is machined for the stgIII turbine wheel in the sc50, so i sent the cossie housing out to be profiled to match.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC170004.jpg)
as soon as i get everything back from the turbo shop, ill have some pics of it all assembled.
i picked up some sprint car lers to gain some ground clearance, and allow me to setup a side exit. the pipe under my IRS diff was really overheating the fluid and i think had something to do with the bearing noises im hearing back there now. im going to a drivers side exit, in front of the rear tire.
the "lers" are 3" thru with 3.5" housings, no packing. they are designed to meet very loose db rules, not really silence so much ;)
i will be running three of them in a row. each is 8" long.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC190001.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC190003.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/PC190002.jpg)
at this point my wallet is hemorrhaging and i cant seem to stop it! gettin ready to place an order for a 3" doughnut to build the turbine outlet, a couple o2 bungs, and a 3" 90 and 45 for my new side exit.
gotta pull the trans and rear diff in order to decide if i need a new PP or just a disc, and get some new bearing for the IRS....
hurry up and wait right now till parts get here, but then i should have some updates as things progress.
Didn't realize you were daily driving your car! Looks like a neat project keep the pics and updates coming. Those sprint car lers will be pretty loud from the looks of it!
You have been busy. We didn't get to chat too much when you stopped by that day to grab the parts. (That should help with a little of the hemorrhaging though ;) )
I'll be curious to see what kind of ling those sprint car pieces do.
the lers are designed to meet the db rules at certain tracks. generally the rule is 100db at 100ft.
the sprints run one of these on each header.....
i currently have two hung on the end of the pipe just to get an idea. keeping in mind there was not a functioning turbo on the car, which will change the sound yet again, i could tell the difference between open, 1 ler, and 2 lers. not so much in volume, but more in harshness.
i will have to find some audio recording equipment once everything is back together.
Well, my camera does video with sound, so that might be an option if you want to record it.
We need to build you a MegaSquirt for that thing :p
Were those first pics taken at O'Reily's?
Looks like advance auto, according to the wall thingy ;)
shiznit, that's gotta be Pep Boys... :D
parts update.
pulled the trigger and ordered some stuff. got the tubing i need for the new down pipe configuration, and a couple o2 sensor bungs.
also ordered up an AEM WBo2 monitor. gonna need it with the bigger turbo so i can start tweaking things to keep this motor alive until i step up to a real tuning solution.
hopefully after new years, i can get out in the garage and start tearing into stuff....too much family junk goin on around this time of year to get anything done!
some parts have arrived
3" doughnut, flex bellow, o2 bungs and plug, WBo2.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/P1040048.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/P1040051.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/P1040049.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/P1040050.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/P1040058.jpg)
advanced, it says on the wall
Where did you get the 3" doughnut? And what is the radius on that thing?
race part solutions
http://www.racepartsolutions.com/products.asp?cat=105
they have alot of good turbo stuff. i run their silicone couplers as well. doughnut is formed on a 3" CLR. tightest center line radius you can get with a 3" tube. my choices were to pay out the nose for a 3"CLR 90* which i could only find one place, and then still buy another 4"CLR 90 and a 4"CLR 45, or just pay once for a doughnut that i could build all three bends from.
eesh, i am really draggin ass on this project. i sent the turbo out to have some machine work done, and turns out it needed rebuilt too.
once i got the turbo back, i started working on my new downpipe setup.
first i cut up the old exhaust and salvaged the parts i wanna reuse
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/8bf8adb5.jpg)
here is the new turbo outlet i built
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/0d1db23b.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/f7b4d979.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/dbb05238.jpg)
and some gratuitous turbo shots!
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/77aa3cb2.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/9bb2d54d.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/861bf20c.jpg)
i also grabbed a set of 46lb CFI injectors while at the junkyard a few weeks back. :evilgrin:
I do like those Cossie outlets.
port matched the turbine inlet and cleaned up the outlet port tonight. also smoothed the transition into the wastegate opening a lil bit.
then more exhaust pipe work
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/fc18af27.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/060cab56.jpg)
almost ready to call that junction good, then i gotta finish my driveshaft project so i can get the rest of the exhaust fitted up.
Looking great Gumby. Now, is that the WBO2 bung on the bottom of the downpipe, or am I seeing things?
on the bottom of the DP is the jack that was holding it in place for the mock up :hick:
welded up that joint, and moved onto my driveshaft project. needed to get it semi-completed so i could install it for fitting the rest of the exhaust thru the tunnel.
i grabbed an aluminum shaft at the junkyard a while back. it was laying out in the middle of a row...someone had robbed the pinion yoke from it. it looked straight and i didnt hafta lay on the cold wet ground to pull it myself, so i bought it. best i can tell, it came from a crown vic. it has the proper ujoints to match my tbird, and had a 4r70w slip yoke on the front.
the stock shaft weighs 14lbs. after cuttin about 8" off this vic shaft, it weighs 8.4lbs!
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/cb166c60.jpg)
ever wonder whats inside an aluminum d/s?? a cardboard tube!
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/2eaced36.jpg)
i also need to find a T5/AOD slip yoke w/o this stupid balancer. this thing weighs 9.6lbs compared to 3.6lbs for the 4r70w yoke
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/1f1607d2.jpg)
new shaft installed(for now). i will find a new yoke, and install some fresh ujoints before this new shaft is done.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/2b754dae.jpg)
with that outta the way, i could move forward with more exhaust piping. here is the system so far, all welded up. there is a slip joint after the first ler to make installation/removal easier.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/9ff16ca1.jpg)
and in the car
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/924940a9.jpg)
money shot down the tunnel, oh the joys of IRS w/a fixed driveline angle!
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/47b789f0.jpg)
still gotta add in my flex coupler, and finish the side exit.
gumby,
two things.
1) that first pic sort of looks like the aluminum shaft is floating above the floor and the (cast iron) stock one is it's shadow.
2) what is that thing at the bottom of the downpipe?
its a bottle jack!
you can see it in the very lower left corner of this picture as well
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/924940a9.jpg)
What header is that?
Looks Awsome
Aha, a jack!
What does the car sound like with the ler (love it, btw). I'd like to do something similar with mine (save weight) but the pipe has to exit after the rear wheels.
the header is one of Rod's.
i fired the car before i took everything apart with an open pipe, and empty turbine housing. i slipped two of these lers on the pipe, but its kinda hard to say what the lers will sound like behind a spinning turbo...the sound was still very open pipeish, but less harsh. gonna be loud i think. definitely alot lighter than the big dynomax i was runnin, though.
im trying to get away from a pipe under the IRS diff. adds too much heat. wrapping it would help, but a cooler is an expensive addition!
thanks, guys!
whacked the lower coolant passage off the bottom of my intake manifold.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/10caa53c.jpg)
gonna weld a plate in the opening, and mount the probe for my mechanical water temp gauge in it. relocated the factory ECT to the original gauge sender port in the block
Gumby, just saw your post on TF about the flex pipe. I'm pretty sure you chose the right position, that's about where I was planning on putting one.
How about posting some audio of the exhaust? I want to hear how that ler sounds.
Gumby, just saw your post on TF about the flex pipe. I'm pretty sure you chose the right position, that's about where I was planning on putting one.
How about posting some audio of the exhaust? I want to hear how that ler sounds.
I did this to mine as well. My coolant sensor for the MegaSquirt is located there.
The exhaust looks good. I'll have to give it a listen here soon.
here is the flex coupler added in.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/058af4f7.jpg)
oh the peer pressure! ;) i need to get it back running before
anyone gets to hear it; including me :punchballs:
that means gettin my intake manifold done....
and here i was thinking i had an original, cool ass idea....i guess it must at least be cool if you already did it:rollin:
got any pics?
my plan is to square up the walls of the port in the manifold and fit a ¾" thick piece of aluminum, welded from the backside. i figure if i weld it on the backside i wont hafta worry as much about the gasket mating surface. the aluminum block will have a port drilled and tapped for the temp probe, which should stick right thru into the coolant flow of head itself.
That's where I wound up with my flex coupler as well.
I must not have any pics of the intake uploaded, so I'll have to do that later. I think I onlly used a 3/8" (maybe 1/2") piece of AL to fill the hole. Any thicker and my sensor wouldn't protrude very far into the coolant flow. How long is your temp probe? 3/4" might be too much if it's kind of short.
the autometer probe is 1.5" long. i plan on sinking the adapter into the aluminum block a bit to make sure the end of the probe is beyond the surface of the manifold.
got some time today to work on that intake manifold
new piece welded in
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/5da6b37a.jpg)
autometer adapter; finger tight
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/577a44e5.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/a12614c9.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/f53af8e1.jpg)
the gauge probe protrudes a lil over ½" past the blue adapter. lil bit of pipe tape, tighten down the adapter, and i should be ready to reinstall the manifold....
Lookin' good, and BTW, that counter top looks exactly like mine.
Except I have no turbo parts to place upon it :rollin:
Looks pretty good. Should work out fine the way you have it.:cheers:
couple pics of my work last night. so happy :hick:
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/e154c576.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/e79d2914.jpg)
took a bit of finagling but i got everything clocked the way i want. i tilted the CHRA slightly so all the bolts on the compressor housing clear the drain line adapter, and got a nice straight run for my drain line. need to add about ¾" to the drain hose for this setup. thankfully i wont hafta change the fittings again.
played around a bit with WGA locations. plenty of real estate to work with, just waiting on my new bracket to show up. i might hafta get an actuator with a bent arm because of the larger diameter of the T4 compressor housing
Nice work!
Looks badass. Makes me want to put the motor that I was building for the Ranger in the Bird thats sitting in the garage collecting dust.
Looks very sweet. Turbo's are so cool.
as per usual, i have side tracked myself. for whatever reason i started looking at wheels again. after i cracked one of my konigs last summer, i was regulated to running a mis-matched set of wheels(konigs on front and tri-bars on the rear) due to my suspension setup and subsequent offset requirements.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/804838f9.jpg)
i could have run that setup this year w/o issue, but noooooo
i have been searching thru wheels on and off, having a difficult time finding anything that fit the offsets i need for this car. with the type of abuse this car sees, i was weary of the inexpensive aftermarket wheels. additionally, i am a cheap SOB and one piece forged wheels are rediculously expensive. another option was OEM wheels. a pair of 05+ bullits on front and a pair of sn95 bullits in back would fit well, but i want to get more tire under the car plus i am anti-mustang wheel; just tired of seeing them on everything.
im sure you can see my conundrum....anyhow.... :toilet:
i was contemplating keeping this under wraps till CJ, but there is no CJ and the new wheels got delivered today....
i decided to go with a used set of three piece wheels for a couple major reasons. one, i can choose my own offsets and two, i ALWAYS change my mind at some point in time.
these are Desmond WiseSports. they are made in puppiesan. puppiesan and Germany have some of the strongest regulations on the manufacture of aftermarket wheels.
they are currently built as 17x7.5F and 17x8.5R. offset is +42. this will allow me to run my current 245/45's this year and finish them off. i will likely run a small ¼" spacer on the rear as i did with my konigs(17x8 +40 all around). this will put the wheels in roughly the same locations as the mis-match set, relative to the fenders.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/1afd7429.jpg)
i was very concerned about brake caliper clearance buying used wheels. there is little to no information about these wisesports online, and nothing about brake fitments. fortunately, they do fit!
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/6a6143e8.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/9e6bdf07.jpg)
i also noticed the lug holes arent oversized like many OEM and aftermarket wheels, and the hub bore is the same size as the sn95 parts i am runnin. no hubcentric rings needed.
this is the best i can do for an overall pic until spring. garage is too small to get any further away from the car.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/16155149.jpg)
they need some lovin, and alot of polishing. the center caps look like they belong on a cougar! the style of the spokes remind me of ROH snypers, one of my favorite wheels of all time. :bowdown:
next year, when i will need new tires anyhow, i plan to move the 8.5's to the front and widen the 7.5's to 9"
this will allow me to run a 255/40, 275/40 tire combo, and get a lil more rubber on the ground :burnout:
me likey!
glad to see it coming along so well!
The new wheels are going to look great!
They look like a pretty good fit for what you want.
We'll need to get the cars together at some point this season for a little picture taking.
thanks guys. im stoked to step up to a set of 3pc wheels. i was very anxious about the fitment, seems to have worked out well.
i had to go to work lastnight right after i posted, and one thing i remembered while i was at work was that my front pads are not new. i checked this morning and they are about half used. when i put new pads on it, i may need to slip a spacer on to clear the new caliper location. thankfully, so far, i havent been eating up the pads too quickly and ill cross that bridge when it comes time. plenty of flexibility with 3pc wheels to make up for whatever small interferences i might come across.
chuck, we definitely need to get these two cars together this year! :birdsmily:
did a lil more work on the exhaust today. workin on the side exit pipe. after the turn out toward the side of the car, the pipe crosses under the raised section of subframe then turns slightly back toward the rear of the car. i am ovalizing the pipe for ground clearance.
not much for pics cause i ran out of argon before i got too far into anything worth taking pics of, but i did grab a couple shots of how i "bent" the ovalized pipe.
a few cuts with the sawzall thru all but the bottom edge
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/1cdd4f06.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/5ef808aa.jpg)
then push the kerfs closed
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/c6a02ec7.jpg)
what once was straight.....
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/b175385d.jpg)
the exhaust is almost complete. the run out the side is finished now. just needs a couple hangers, and to cut the tip off
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/3583fabf.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/0d8f10d5.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/c6ac0578.jpg)
also got a WGA bracket and finalized the location of the actuator and oil drain line.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/a13502fb.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/86459eff.jpg)
the turbo is on the car in final form. hopefully this was the last time i will hafta install the turbo this year... (http://www.turborangerforums.com/images/smilies/turbob.gif)
That's almost exactly what I wanted to do, but south of the Red River the pipe has to exit after the rear axle. Shape it like a flat oval, that will be sweet.
BTW, love those wheels.
buttoned up a few things, and fired the car up this afternoon. i really wanted to hear the new exhaust before i pull things back apart to swap the clutch.
go easy on me, i just figured out my wife's ipod can shoot video w/sound and this is the first thing i decided to do with that knowledge! :hick:
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/th_b54a8649.jpg) (http://s25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/?action=view¤t=b54a8649.flv)
Pants=tight.
well, i guess this explains the clutch slippage that started last summer
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/1b3e11ef.jpg)
just ordered a new 4puck disc from clutchnet, and a pressure plate from pyropete. picked up an escort flywheel yesterday.
NEW PARTS!!
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/225d20b7.jpg)
also added some fresh ujoints and an AOD slip yoke to my aluminum d/s. for whatever reason, ford put smaller ujoints in 5.0 cars than in the turbo cars. i had to use a 1310 to 1330 conversion joint on the front.... i guess if i find a 1330 AOD slip yoke down the line someplace, i will swap it out later, but this one was free.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/44624bec.jpg)
hopefully ill get my flywheel back from the machine shop tomorrow. i had them redrill the escort flywheel for the larger TC pressure plate. i thought about doing it myself, but they have a fancy CNC mill vs. my access to a manual mill, plus i dont have a rotary table at work. i figured a couple hours of my time is worth about what they charge me to do it up in about 15mins and just be done with it....
mmmmmm tires swapped over onto the new wheels.
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/90b18916.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/a17e8f45.jpg)
and here is what ½" difference in rim width can do to tire fitment. on the old 8" wheels my sidewalls were perfectly square
7.5" fronts
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/e8587bef.jpg)
8.5" rears
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/b6309b08.jpg)
oh to hell with updates anyhow.......its alive again, finally.
took forever to get my flywheel back, got it installed, fiddled with the pivot ball stud a lil bit.
installed trans and went to install the d/s. found out the yoke i got from a buddie was twisted and wouldnt let the d/s go forward far enough to connect to the diff.
pulled the diff to replace a noisy pinion bearing, and found out it was way worse than i thought. ended up pulling the diff and replacing all the bearings.
got a different slip yoke from the junkyard, and reinstalled the new aluminum d/s again.
finished up the hangers for the exhaust and slash cut the tip.
buttoned up a few other things today, and pulled it out into the driveway. havent gone for a ride as yet, still need to get some gear oil....
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/0c598593.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/624dfc63.jpg)
(http://i25.photobucket.com/albums/c73/gmby23/87%20turbocoupe/b0042f35.jpg)
got a list of lil things that need attention this summer:
install my wide band o2
reinstall my gauge panels
modify and install a solid steering shaft i picked up
build new mounts for my e-fan
install some 46lb injectors i have here and see if i can make any more power before i commit to head work and a tuner
etc etc etc, i wont even get into my plans for next year....this thing is never completely finished. :hick:
Those wheels and that stance is just pure awesome.
Man that looks sweet!!
Yay!