frayz

Cheers bars

frayz

Not much to update this at the moment. Im waiting to get my sump back as thats been away being baffled. Also waiting on my modified AVCS line and other parts to be zinc coated. Once these are on i can go ahead and fit up all the timing assembly.

Also wonding if i should bother buying the Cosworth/RCM anti skip belt guide or not?
£40 for jewellery or function?

In the meantime ive fitted up some of the water, breather lines and reassembled the alternator and PAS pump. Both look rather nice all powdercoated up

JonnyBravo

Superb !

Thats some lovely work going on there.

turbomook

iTrader: (4)

Nice work mate.. Alot of time and effort is going into this

frayz

Cheers guys, much appreciated from you Fordys

As said, im a bit stuck till i get more parts back, but heres the rebuilt alternator and PAS pump.

frayz

Well not much to update. I should get my oil pan back tomorrow and i picked up some other modified pipes etc tonight so these will be droped of to be plated tomorrow also.

In the meantime ive had a delivery of a full set of timing idlers (cheers Alyn @ As Performance - top service as always)



Drilled/tapped my X-over pipe to take the Defi water temp sender.



Made up a feed/take off for the Defi oil pressure sender and retain the OEM oil press switch.



Made up a boss to take my air charge temp sensor that replaces the OEM PCV valve that will no longer be used.



Removed almost all bosses from the manifold and refinished in wrinkle red (original VHT shade)



Generally mocking stuff up. Some of the above parts are loose assy untill i get the pipeworkl back. As soon as the modified pipes come back from plating i can progresss quite alot more

JonnyBravo

Engine looks superb !

Where did you get the crackle paint from, its near enough for what I need for my Honda lump.

frayz

Jonny its VHT wrinkle red part number SP204. Its avaliable on eBay and frost.co.uk.
Its also available in black.

http://cgi.ebay.co.uk/VHT-RED-WRINKL...item3a5576f0ba

Although notice i said this is the old shade, its darker than the new formula. VHT changed the formula approx 2 years ago and its now a much more orange/red.
Having looked at it though as i base coated this manifold in the new shade, that if you didnt have the 2 colours side by side then the new shade would still look fine.

Get some and try it out, works best with heat too, so get the hairdryer on it.

Hope that helps

Mike C

iTrader: (1)

Think I'll try some of that in black for my inlet manifold. Looking well!

JonnyBravo

Top stuff, thanks for the advice

frayz

Started mocking up where my oil cooler will sit.

Hopefull have a nice ram air duct feeding this.

frayz

Okay i feel i have a more healthy size update for you guys today, so heres part one.

You may remember me having fitted a 76mm itake trumpet into my OS fog cover about 5 years ago now. I wanted to do the same on the NS in order to feed the oil cooler. However this time i wanted to try and have a more OEM look so wanted to have the bellmouth intakes but wanted them to look stock.

So i enlisted a friend of mine at work who makes prototype body fabrications etc and he said he could make them up for me.
Well today he delivered these to me, and what a great job he has done too.

He is also going to make me a shroud for my oil cooler so im looking forward to seeing that soon

whizzisat114

iTrader: (2)

jesus christ they look the dogs

frayz

I took some parts to be zinc coated yesterday and i told the guys there that i wanted them done double quick. Sure enough they called me at 1pm today to say i could collect them.
The black zinc came up real nice. Heres my pan with baffle in black zinc and gloss black powdercoated outer case



AVCS lines modified for turbo oil feed and modified water feed with AN fittings also in black zinc.



Lines all fitted up.





Cosworth windage tray and oil pickup fitted.



Then on goes the oil pan



Then new Apex engine mounts



With the AVCS lines finally fitted i could get the timing covers on, fit the sprockets and get her all timed up. Kevlar belts are damn tight but go on with a little push.



As i left it tonight, im waiting for an RCM belt guide to come through then the timing covers can go on. Hopefully get some more done tomorrow. But with the intake manifold rested on its starting to look quite smart and like an engine again

Rob_DOHC

iTrader: (4)

that looks bastard expensive, good work mate and hope all goes to plan

frayz

Lol, it is bastard expensive Rob.
My cossie could have been a million bhp with what this thing has cost me. I just hope the bloody thing works lol

B19 JUB

with your knowledge frayz im sure it will work and work well.good to see u still around and carrying on with it

frayz

Cheers mate, ive decided to unpick the entire engine loom because i can get it to look right. Grrr

frayz

I started to fit the engine loom the other night and it wasnt long before i thought how awful it makes the engine look. Subaru made a right shambles of a job when creating a nice routing for it.

So not happy with it making my motor look horrid, i decided to completely unpick the whole loom and reroute sections, lengthene sections and shorten others.

Its not a pretty job

RS Grant

iTrader: (1)

I get the impression that this car's a keeper Frayz...

Little touches here and there that make the difference mate and your car is full of them... always enjoy keeping up with the progress on it, interesting to see how you get on with the custom (tucked?) loom idea too.


Cheers,
Grant

frayz

Cheers Grant,

I dont think i will achieve a tucked loom. Well not what i concider to be a tucked loom. Like the VW boys do. Unless i have a full motorsport loom made exactly for my motor but im not prepared to go that far. I just want to route it all as neat as i can with what i have.
In the impreza bay its almost impossible to hide the loom. I just want it to look neat on my motor and not an eyesore like it is at the mo lol.

frayz

As you know I enlisted the help of my friend Ian to modify my foglamp covers to intake ducts. Well he did a super job of those and today he brought me another gift.

He has made me a duct to fit my 19 row setrab oil cooler. This is a tight fit over my oil cooler and will force feed the core from one of the foglamp cover ducts.
This will now be mocked up in place and then i can cut a hole in the front (square section)to run a hose into the duct from the ram-air ports at the front of the car.

He even managed to form it from some funky carbon effect plastic. Cheers fella, youre a star.




And as for the engine harness, well i decided it was awful in stock form so heres how it looks right now. lol. Im spiral wrapping all take offs and then sleeving them.
Looks horrid at the moment but i have faith it will look pretty neat once complete

carlo

iTrader: (4)

Getting there mate nice one

frayz

Cheers Carlo

Oil cooler duct tried in for size. I think i measured that about right. Lol

Need to cut the hole in the front once its all bracketed in.



Loom starting to take some shape now.

frayz

Had to machine some more off my home made fuel rails.

So now they look like this

frayz

Been quiet a few days now guys.

Basically i got 99% of the engine harness done. But i still wasnt quite happy with it so decided to tear it all back and start again. So i am now mid way through my 2nd time at doing it and im now really pleased with how its turning out.
I have made a small sub assembly harness up just for the cam/crank sensors, this i have finished.
It was much neater to do this and take the plug over the gearbox as it keeps everything around the turboside much much neater.

The main harness is now almost complete and ready for sleeving. I have done away with the stock harness gutter and its all looking much neater.

Im really liking the new look.

frayz

Okay guys, i ran out of large heatshrink on the last few joins so i'll get some more of this tomorrow. Other than that the new harness is pretty much complete.

I laid it on just loose and so far it seems to fit good. I need to add P-clips and zip ties etc when it gets fitted for real. Admittedly im no expert loom builder or electrician but so far so good.

frayz

Finished the harness off guys and started making up the breather pipework. I need to get a couple more fittings for the breather and then i can get the manifold finally bolted up. Then i can clip all the haness and pipework in place, then make up my fuel lines.

Also dummy fitted my filter to check how much i have to move the header tank.

Things are starting to look interesting






Knocked up a header tank relocation bracket. RCM inspired and fits quite nice.
Another item to be chucked in the powdercoat box haha.

Funds are slowing progress, but im doing what i can

Red16

Superb work, everything looks top drawer!

I need to make a loom soon, so it was good to see your photos. Where did you buy that loom overbraid stuff? It's just what I want for mine.

whizzisat114

iTrader: (2)

Yeah i could do with some of that over braid for my loom aswell , what's it called and where did you get it from?

frayz

All my stuff came from here guys. Awesome service. All my stuff always arrived next day

http://www.vehicle-wiring-products.e...e/homepage.php

Twins

iTrader: (18)

Looks great ,same over braid i have on mine

frayz

Ordered my first lot of fuel fittings today too chaps so i can get the fuel system started. Then i can look at getting the motor dropped back in the bay and get some tanks made up

Gadget

Looking real tidy Frayz, Just ordered some black wrinkle black for my rocker cover and inlet!
Love the oil cooler scoop. How's Ian doing anyway, not spoke to him for ages. If i lived closer, i'd have loads of bits for him to make lol. Gonna put a decent size battery in the boot and get rid of this kids 12v ride on battery, make a nice enclosed air filter box with direct feed from the n/s bumper scoop!!
Say hello to the build bay lads for me. Cheers.

frayz

Ello gorgeous, how are ya?

Yeah Ians cool, he's always helping me with stuff. He's too talented to waste doing the day to day gear.
Get some pics up of the heve-ho, always interested to see what youre up to. When its build i'll come up and see you, it'll need some running in miles anyway

frayz

Well proto #1 has been made of the RCM style inner wing insert. Its a slightly different style than the RCM one. Its deeper and will take a larger dia cold air feed, mine will be 83mm fed direct from one of the foglamp covers.
This proto is to my original drawing and does not yet have a feed to it.
I'll fit this first just as an insert and then make any changes that are required before adding the air feed in the bottom. Huge thanks to Ian for knocking this up double quick. I only gave him a drawing yesterday




Also another bracket that needs making... "can ya guess what it is yet?"

frayz

Double quick turnaround from Ben @ Hel Performance ensured my hose and fittings arrived for the weekend. The ones in blue are only available in blue at the moment so they will more than likely be taken to be re anodized in black to match the rest.

Oh remember that bracket?

Well now my regulator has a home

frayz

Ive dummy fitted the proto wing insert today and over all im absolutely delighted with it. It does need some slight alterations, one of which will be to make it taller by approx 20mm. But even just resting it in there with tape you can see it will fit excellent once finished.

I think this is the most exciting thing on the car in ages. Once proto #2 is made we can get the air feed right.

What do you think guys?

frayz

Made up most of the fuel lines for the parallel setup tonight. The small line im not happy with which will be redone (thats why its not Nomex covered).
Amazing how time consuming making these up is.

I was dead set on getting the blue fittings anodised black but now im 50:50.

All requires clipping in place and tightening up but i think looks alright at the mo. Once these are complete. The engine is nearing completion and wont be far away from being dropped back into the car.

Exciting stuff eh?

COLEYST200

iTrader: (3)

very very nice