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I picked up the inlet manifold from the workshop and started to polish it. I have cut off all of the lugs that are not going to be used. I have finished about half of the manifold and I am really happy with the results so far.

I had a look at the same conversion in a Kombi, and the guy really knows how to do a professional engine swap. Would have loved to have a ride but it's a customers car.

I will keep you informed of the progress.
I thought it would be a good idea to post an update on the transplant.

We are almost there, the motor is in, we are down to the final details.

we turned the inlet manifold through 180 degrees, this allows the inlet pipe from the Charge cooler to the throtle body to fit without having to cut the bulkhead. The boost pipe from the turbo to the charge cooler is in, the exhast manifolds have been manufactured, the only part of the exhaust remaining is to fit the rear silencer box. We have a nissan 350z stainless box which looks as though it will be a perfect fit. ( i am a bit concerned that the two huge outlets might not look the part on the car but we are going ahead with them anyway.

The cooling system is ready, We have 2 fans mounted behing the radiator, these will be controlled mythe engine management system. The engine management system will cut the motor if the temps get out of hand!

As I mentioned before the engine management system has two mappings, one mild which will have a boost limit of .4bar boost and a potential limit on revs and second mapping which wiull deliver the maximum performance.

These mappings could also be used to adjust the performance based on the octane level of the fuel available. (We are at 5500ft above sea level so we have 93 and 95 octane fuel available)

The guys doing the transplant are expecting to fire up the car within the next couple of days. He has promised to call me to witness the event.

Prior to taking the car to the dyno, the car will be idled in the workshop to check for leaks etc in the cooling system. When the motor is being programed on the dyno additional probes are used to monitor temperatures and pressures.

I also collected an alternator which I will start polishing tonight. It must also look good!

I will try and post a couple of pics with the next update
Things are looking good, It won't be long before the motor is fired up for the first time. The cooling system is complete, It has water in it and only one minor leak requiring some attention. The charge cooler radiator needs to be fitted although the plumbing has been done from the back to the front.

Still outstanding is the Throtle cable, crankshaft sensor for the engine managemnent system (first one fouled the crankcase), cambelt and covers, dumpvalve and aircleaner. the fabricator has made up three differnt aircleaner options and keeps changing his mind. I don't mind as I can see he is trying to find the best package without comprimising performance or appearances.

Our local performance magazine (speed and Sound) is coming around to the workshop on Tuesday to take some pics and do a bit of an article on the project so I expect that all of the loose ends will be attended to by then

The anticipation of final driving the car with it new heart is killing me!

I have to say at this point I am really glad I did not attempt this conversion myself as I miss judged the amount of effort required to do a half decent job
Hi tom. Sorry i havent't posted any pics as yet, I have taken a couple of them already, but getting them posted always seems a drag. I will post a full overview of the install as soon as it's done. I think quite a few guys are going to be impressed with the elegant install!

By the way I really feel your pain that you have gone through with your coupe. I discovered the history on the forum and it made for quite painfull reading. I have to say though from the pics your car is absolutely geogeous and I dream of owning something similar in the future.
Hi there

Just want to let you know we started the motor last night! It took about half an hour to set up the engine management system. The guys really know what they are doing. It will be going onto the dyno today to do the proper tuning. The last of the bits and pieces should be finished by this morning. These include fitting of the radiator fans and the charge cooler radiator. So it looks good that I will have the car back by the weekend. When it comes back from the dyno he will polish up all the stainless boost pipes etc.

I polished the alternator and painted the stator. You have no idea what a difference this makes to the appearance of the motor. When I look at the hours the poor guy has spent on my car I can
there were a couple of small details which took a bit longer than expected (why am I not suprised!) to finish up so the car did not make it to the Dyno yesterday. But the good news is that it was loaded onto the flatback this morning and it is now at the dyno. I will get a call a bit later today to get me across to witness the big event.

More info to follow as soon as I am back.
If you are impatient about waiting for more details, spare a thought for me! I am going of my mind.

The car finally made it onto the dyno on Monday. A basic map was loaded into the engine management system and the run was started, as expected the graphs were all over the place, the peek power was recorded at 120kw on the wheels, but then disaster, well not really, water was found to be leaking into the oil through the head gasket, so it was back to the workshop to pull the heads and fit new head gaskets. This was done yesterday and I managed to drive the car last night for the first time.

The motor was pretty rough below 3000rpm but then would run clean through to about 6500rpm. WOW, this might even be more than I bargained on, the steering goes pretty light (maybe non at all!)

there was a lot of squat under acceleration so the proposed Z bar might have to be tightened up a bit more than planned.

I only drove it for a few minutes so I can't really give you much feedback.

the car is currently at the dyno and are expecting to get it back to tonight.

In the workshop we checked everything again and again. At first I thought that we had problems with the cooling system as the temporary temperature gauge tended to over read quite a bit. We verified the temperature with the diagnostics software on a laptop which showed a more realistic value. In fact only up to 95degrees C. Sorry I can
well it was bound to happen. We have encountered some cooling problems. When we finally made it back to the dyno it was a typically hot summers day 32 degrees C. within about 3 minutes under load the temp gauge started climbing and excess water was pushed out the expansion tank. We aborted the run and let the car cool down. We found that we had a large difference in temp where the water goes into the radiator and out. One side you could touch and the other too hot to touch. We pulled out the thermostat and found that it was still open. we then put the car back onto the dyno and there was a significant improvement. the inlet and outlets of the radiator where now pretty similar. We could now start mapping the fuel curves. We would do a run and then let the car idle for a coupe of minutes to allow the temps to cool a bit. Then in the middle of a run at about 4500rpm there was a terrible noise, the operator of the dyno eyes looked like saucers! fortunately the cause was the alternator drive belt which let go. It turn out that the tensioner pulley was slightly out of alignment.

There was still enough light left to drive the car back to the workshop. The motor was not completely set, the fuel mixture above 4000 rpm was still set very rich and the timing on the safe side of optimum. All the same, what a blast. The idle was set a touch slow so it would stall every now and again. The sound is magnificent. I can tell that it is going to be more than I was hopping for.

We are going to raise the battery a bit to allow a more direct flow over more of the radiator, make a change to the inlet side of the radiator (cut away a small part of the bumper below the number plate and tweak the design of the scoop under the car. We are also moving the expansion tank up another 20mm, we are going to drill a 4mm hole in the thermostat to make filling the cooling system easier, Tidy up the wiring and a few loose ends on the conversion. The dyno will only be available on Thursday next week so we will make sure that everything lse is perfect before then. I will be taking the car out again on Tuesday to do some mor testing on the cooling system so that we wont have any cooling issues during the dyno run.


I will post again on Tuesday
Well last Friday we had the car back at the dyno. The cooling problems are not completely sorted out, however we were able to get the tuning done with a couple of breaks in the middle.

The first map to be tuned was the low boost map. Here the boost was limited to .3bar. We left the rev limiter at 7000rpm, the map was set at intervals of 500 rpm increments, once this was done we went through the maping and made adjustments at 100 rpm intervals, albeit very small adjustments, then it was onto the power run, this is the part that gets pretty exciting, the car is run up to third gear, the dyno is loaded up and the motor is run through to the 7000rpm limit, The rear of the car squats down pretty hard and the noise is incredible, over the noise of the exhaust you hear the rush of air into the air filter, WOW. Any way these are the figures you are looking for 147kw and 220nm of torque! Not bad for very low boost setting.

Now onto the .7 bar run. The fuelling map is adjusted using a lambda probe stuffed up the exhaust pipe. With the extra boost more fuel is added as required to keep the readings within spec. The power run hear is as follows 182kw and 280nm of torque.

These figures are actually pretty good for the standard WRX sti motor.

The internals of the motor are said to be safe up to max boost pressure of 1.3bar. They say that 240kw would not be an unreasonable expectation. who knows, maybe one day I might want more power and start to play again.

We have a small problem with the management system that prevents us from starting the car in the high boost position. They expect that this will be resolved but if not it is not the end of the world as 147kw is not to shabby.

I got to drive the car over the weekend, although I had to keep an eye on the water temperture. The engine management system was set to cut the motor at 107degress C and I managed to keep it below this level without too much trouble.

Driving Impression.

Well how the hell do you try and describe the experience of driving a car with a power to weight ratio of about 200watts per kilogram. The car launches pretty easy, getting the correct amount of power with a touch of clutch slip gets the car moving very quickly, 1st gear is over in a flash and you change to 2nd , the dump valve makes an almighty whoosh, the turbo keeps spinning and you release the clutch, Now things get pretty serious, the motor is on boost and the level of acceleration is mind blowing what feels like seconds later you are approaching 60 miles an hour and you change to third, the dump valve blows of and you release the clutch and bury the throttle and then tragedy! The clutch can
Well here is some much anticipated feedback! We installed a much thicker radiator and a very powerful fan, It looks as though the cooling issues have been put to bed. The new clutch needed some adjustment but now seems to grip pretty good, I am able to drive in a normal manner, i must admit I was a bit worried up front about the copper clutch being difficult to modulate but it is just fine.

Last night I was working late at the factory and left about 21h30. The car was running beautifully and I decided to take the long route home. There are a couple of traffic circles which are great fun to push through, the road surface is perfect, there were no other cars on the road and I sliced my way through the circles with practiced ease... I buried the throttle in second gear and just before changing to 3rd there was an almighty explosion, SH1T double sh1t. my first thought was that turbo boost pipe had come off under full boost, but I was immediately engulfed in a huge cloud of white smoke. The motor sounded very rough, it almost sounded as though the exhaust manifold had come off! I immediately cut the motor and pulled over to the side of the road. I bailed out with the fire extinguisher in my hand (after reading a post a month or so back about engine fires I went out and bought one) and opened the bonnet quite expecting to see flames everywhere, after about 2 minutes the smoke started to thin out, I got out the torch and found a huge puddle of oil lying under the motor!. it didn't take too long to find the damage, the number one cylinder rod separated at the big end, what a fcnkiug mess!

My next thought was to have to phone my wife to get her to come out and tow me home. this I have to say was quite a daunting thought!!, but then I remembered that my staff had just been dropped of by one of my assistants and he got the call.

This morning I took the car back to Marius and he was very surprised. We have agreed mutually to go half on the cost of the motor and no charge for the labour. This will cost me about US$ 350! I think he has been pretty descent as he can't be held responsible for a second hand motor. He has another motor on the floor at the moment and he says he should have it installed by Friday. Now that is what I call service!!!

I have attached a before and an after photo for your interest. I must say I am pretty happy with the look of the engine bay (well the before photo anyway!) Down the line I am going to install stainless braided hoses everywhere)

So much for the reliability of a modern standard engine!

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  • motor before 2
  • motor after
I went past Marius at lunch time and they have already installed the replacement motor! He says that it will be ready in the morning. Now that is what I call service. He did say that as I made the motor dirty I would have to clean everything myself! I am looking forward to polishing it all up again this week end! Actually I am a pathological liar! I am looking forward to driving it all weekend and having it cleaned on Monday!
Well Greg,
my tongue is just hanging out there waiting..... you make me feel like getting on a plane and coming over and joining in, but as you know I have my own set of problems, but boy, its impressive how fast you move, I think you better send Marius out to OZ for a few weeks, makes me feel ashamed of the snail pace I seem to be moving at with my build, :+( however. I have to say your emails inspire me on and you deserve a great result, keep it up and please keep us up to date. Mate what size are those tyres and wheels your going to fit ?

Regards from the Land Down Under

Bill

PS WARNING Look out America... we are already planning our trip back over to tour again .. loved it last time

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  • hanging out
Hey Bill. Thanks for th words on my progress. I am going to be fitting 225/40-18 to the car. I went past this afternoon to pick up the car and there was a littl bit of work to do on the wiring. The car was started and boy does it sound sweet. I think we must have had a poor coil pack on one of the cylinders as the idle was a little rough. it is so smooth now. I can't wait to drive it
again.

I will post again on monday. regards
Hey Bill. Thanks for th words on my progress. I am going to be fitting 225/40-18 to the car. I went past this afternoon to pick up the car and there was a littl bit of work to do on the wiring. The car was started and boy does it sound sweet. I think we must have had a poor coil pack on one of the cylinders as the idle was a little rough. it is so smooth now. I can't wait to drive it
again.

I will post again on monday. regards
I picked up the car on Friday. It was still good and dirty in the engine bay as promised, It felt very smooth at low rpm where the old motor was slightly rough. I expect that the ignition coils on the old motor had been hurt during the tuning process. Apparently the engine management system determins how long to supply power for enough time to charge the coil, I suspect that it might have been set for too long. I am told this is a common problem when using a stand alone management system.

Back to the new motor, well it runs pretty good although I suspect that it is not quite as strong as the previous motor. But I must say it still goes like stink! You can ask the guy in his fancy new BMW M5 V10. I am sure he is still wondering about the little black car that gave him a hiding to 80km/h.

We appear to have the cooling system under control now. The water temp stays at 95 degrees C. It is still a bit warmer than I want but it remains constant whether I drive hard or not slow or fast.

I have ordered a remote oil cooler which we will fit in the next couple of days which should be good for another few degrees.

The new fibreglass fan shroud with 2 10" fans should also help a bit.

I must also get around to putting on a new front number plate. I got pulled of by the traffic cops on Saturday but managed to get of with a warning of a US$80 fine.
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