mk2 Escort - SR20DET

[kenneth]

well new here and new to the whole japs to be honest.
i'll stick up a thread on my drifter project. mainly for retrostock days and Kartworld days.

i have a mk2 escort which have been building for drifting.
i will copy and past the project from the Escort Club just to bring you guys up to speed with where it is now.
hopefully some on here might find it interesting :D


its a 4dr mk2 escort which i plan to fit a SR20DET to and make it some what road legal :D

i'll just add some pics and of whats gone on and i'll update from there as i progress.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/IMG_2257.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/IMG_2255.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/mk2_4door002.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/IMAG0150.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/2011-08-21200110.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/2011-10-21173210.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/2011-08-26192218.jpg[/quote]

[kenneth]

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/a01b23e7.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/e51a02c9.jpg



was gonna fit this but then the plan changed

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/ccb88e3e.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/7784baec.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/e9e85966.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/2c787d5a.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/9b73c03a.jpg


then came the new engine choice....


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/2012-02-04121816.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/2012-02-04121920.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/e6a58f5a.jpg

[kenneth]

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/d4c432de.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120312_200341.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120312_213928.jpg[/quote]

[kenneth]

Now thats all up to date.

so during the week a lad in the escort club made me a custom alloy fuel tank to my own spec and it holds approx 8 gallons.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/63fdc7f8.jpg



and he also flocked a dashtop for me which turned out excellent.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/417088b3.jpg[/quote]

[kenneth]

well spent all day at the 4dr today

firstly finished the diff. surely welded enough now :D

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/bb609ac1.jpg



and spent the day fitting all the running gear.
fitted diff, halfshafts and axle
fitted all front suspension except a steering rack as the one i have was fucked.

so anyone got a free steering rack going??

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/8b09d122.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/0f26ed3a.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/a8b7fbdf.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/5cae1b9c.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/115282bf.jpg



plan to get more done tomorrow

[kenneth]

and some more random pics i forgot to stick up.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/7973cb1d.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/87045c74.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/74ad910e.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/ebf6981f.jpg[/quote]

[kenneth]

well the turbo was fooked in the SR20 so i got a new one and fitted it today.
my god what a pain in the hole that job was

old one fucked

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/85b844ba.jpg


new one

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/61aff430.jpg


and a video of it working again. click the pic.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/th_cbaf9fda.jpg (http://s197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/?action=view&current=cbaf9fda.mp4)

[kenneth]

got the bulkhead gussets in and then ran out of gas....
also fitted the rollcage but must make up some base plates for the legs.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/97a3c78e.jpg

[kenneth]

well i have been collecting wheels this week.
so far i have got 10 15" wheels, and thanks to benny hogan for his efforts to find which cheap wheels fit a unarched mk2 and it turned out to be pug 406 or citroen.

the pic shows the wheel on and they are gonna be perfect but it has a 195/65/15 on it so i will get 195/50/15's for them as they will have a lower profile


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/33d07d50.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/f9c8cb50.jpg



now to the final colour choice........





i have decided to go with NATO green for the body.
i tried bright green for the wheels but i now will go with matt black.
this is only thrown on rough to see the colour. bonnet is finished but it is wet in this pic




http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/8a066197.jpg


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/5974ea3a.jpg





vincent is calling over on saturday to weld in the cage. :up:
and i realised i forgot to weld in the tramp bar brackets to the body.
i might go with an A-frame setup like benny did on his.

also on the look out for stiff rear springs if any one was thinking of going back to road springs or 6 linking please let me know.

[kenneth]

well today Vincent (whitedog) called over to weld in the rollcage as i want the welding to be good on the cage for safety

so he welded in 3mm plate on the arches and front foot plates and the some 8mm under the centre bars.
the welding is shit hot and miles ahead of anything i could ever achieve. :up:

also have a brake set up decided but i'll explain that later in the week when i try put it together.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/77915378.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/368d0b9e.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/da0940e4.jpg

[kenneth]

so needed a few bits and went down to Gary Gallagher for some stuff.

i got a 2.2 quickrack
rack bushes
.70 master cylinder for hydraulic clutch
some link bars to make an A-frame kit
and a T-pull for the cutoff switch

waiting for caliper brackets to come back from the laser cutters to make my brake setup.



http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/1f6a6f87.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/be1051f4.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20090bf0.jpg

[kenneth]

thanks to Dion i got a push start button, ign on switch & a proper kill switch


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120627_220652.jpg



thanks to Dermot for the mondeo front caliper and paul for the cossie disks, just need a bit of lathe work to make it all fit.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120627_220556.jpg



and started on the the power steering setup and just need a lathe to finish it off.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120627_223320.jpg

[kenneth]

as i am planning to run an A-Frame rear axle location i need to use a standard rear anti roll bar.
so philrs had a car that i could get it off of. :up:


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/1b3238c4.jpg

heres what i was after.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/67a82c0e.jpg


and the quick way to get it out was cut it out :D
just need new bushes in the ends of it now

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/23f02d9b.jpg



got a hydraulic clutch pedal box and fitted it today.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/17013803.jpg



and was a bit bored so i tried to make a hole flare tool for free :D
i used a wheel stud and nut and a large nut.
i drilled a 16mm hole and this is what i had.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/53fd9fbf.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/cf354011.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/10c76916.jpg[/

[kenneth]

so made a start and finished my power steering setup.

had the escort spline welded to the corsa spindle

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120704_225814.jpg


then made up all the rest and vince Tig welded everything up proper

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120706_221340.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120707_005013.jpg



vince also tried to teach me to tig weld but i've a long way to go to match his work

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120706_224153.jpg




next was to get it fully rolling as the engine is going in this week.
just need to fit the a frame and rear anti roll bar

this is the front suspension setup and my final amount of lock aswell

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120707_004806.jpg


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120707_004921.jpg


painted the engine bay silver as thats what i had :D


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120707_004947.jpg




dropped the 180sx and escort over to Iain and he will fit and get the engine up and running for which helps alot as these jappers are a bit of a mystery to me.

my brake setup is all ready just waiting for the caliper brackets from the laser cutters still as they got severely flooded losing €€€€'s in equip. so just being patient

hopefully the next update will be running car.

[gary g]

well done mate a fair amount of effort going into this!!

[Paddy drifter]

ah garvans old 180sx ,
nice project ya got going there she will be sweet when shes finished :)

[tom.com]

Epic build!

[kenneth]

i dropped a murphys tap off to vince and this is what he made for me, it's pure class



http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/8ee976cb.jpg

[kenneth]

intercooler fitted

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/6080a06f.jpg


BMW E36 rad fitted

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/4ff9076e.jpg


battery in boot

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/ffcd8ecb.jpg



engine mounted off the xmember on homemade mounts using the nissian bush.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/IMG_4211.jpg


gearbox xmember


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/IMG_1218.jpg



engine mounted


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/IMG_0488.jpg

[kenneth]

well the engine is in and all pipework fitted.
spent 3 days 11hrs a day with Iain working on her.

fuel tank is mounted in the boot and all the wiring is finished off.
having a problem with it as it keeps cutting out but Iain is on it so hopefully figure out the problem.

prop was made by Shaftec and it is a perfect job all new from scratch.

also fitted the front brakes, mondeo caliper, 283 cossie disc, homemade brackets.

bodywork is finished too but i'm not painting it for WGH but will be painted for Mondello (sorry took no pics)


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-1.jpg

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http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-13.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-14.jpg

[kenneth]

front brakes are on cossie 283mm disc and mondeo caliper.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120813_175441.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120813_175449.jpg


at the moment im doing brake lines, its a great help to have the proper brake flaring tool. makes perfects flares first time every time

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120815_170911.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120815_171033.jpg



and some pics of the body panels fitted back. iain did the panels for me as my attempt was desparate.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120815_160115.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120815_162342.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120815_162359.jpg



video is being uploaded now so will stick it up later

[kenneth]

so here is where im at now.

handbrake fitted.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-29.jpg


must say huge thanks to Don Giles who got me sorted for the power steering ECU on friday morning
he has it all pre made now so its a plug and play job. just give it power.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-21.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-15.jpg


vince made up a new A-Frame kit and we mounted it to the car. it worked out perfect but i need to add a rear anti roll bar to stop the nose picking up.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-25.jpg


interior for now

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-32.jpg


finished engine and all pipe work

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-28.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-27.jpg


then over to the local garage to dig out some tyres :D

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-24.jpg


loaded up for watergrasshill on saturday.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-23.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-22.jpg



so got to watergrasshill and had a few teething problems but got out and tested as best i could.

i had a wrapped disc at the front so the brake judder was pretty bad.
i had 1 coilpack give up so she ran on only 3 cylinders.
then i had the hydraulic handbrake which would not work so need to bleed it out proper.
then a pipe off the cooling system came off so i called it a night.

but the main thing is i now know what i need to do before retrostock


some pics out on track


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-30.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-31.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-26.jpg

[A.O'Neill]

Looking good lad,that has got to be the coolest wand iv ever seen!

[Mongey]

savage idea!! im loving this car

[kenneth]

thanks lads

this is up to date now.

well Retrostock has come and gone and what an awesome day it was.

i was flat out for the week before retrostock getting it ready and painted so never did an update.
so i'll fill ye in on where it's at now

so first up was a change of axle as i wanted to run a rear anti roll bar and my previous axle had no mount points for them.
so axle out new axle built with strength added to the spring hangers, a-frame brackets made, caliper brackets welded on.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-41.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-42.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-43.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-44.jpg


next up was the most important job that was making a proper bulkhead and tunnel.
so vince welded in a complete new bit .

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-45.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-46.jpg


then it was time to make an exhaust. so bought a lenght of 63mm pipe

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-49.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-55.jpg


then vince made a sweet oil catch tank.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-52.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-53.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-54.jpg


and finally got out in mondello here are a few pics of it on track.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-63.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps3339a3c2.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-64.jpg


at mondello i had a fair few problems.

to start with i went out for the grip laps to make sure everything was ok but was only get 0.2bar boost pressure but after 4 laps i had that sorted and was set at 1bar.
this was class as the power was great and i was fairly excited at this stage.

so out for the first drift laps and after half a lap the thing was back running on 3 cylinders
so changed coils, plugs, injectors and none fixed it.
got a multimeter from dermot kyne and had 12v at all the coils so was completely stumped as to what was wrong.

so i decided it had enough power with 3 cylinders to get back out drifting.
so had a few laps with some nice drifts and then down the straight the radiator burst so thats when i called it a day.
there is a video of it bursting on my facebook page if ye want to see it.

so i have a few changes i want to make before i get out next but the first thing is to get this engine running correctly

[marksull]

cool build, serious amount of work gone into it. what sort of engine was the one you were going to use initially?

[K series steve]

i love it!!!!some built man,crazy work gone in there,fair play to you!!

[martycturbo]

great project,, some good work ans smart thinking gone into this from what i can see,, will be even better when you have all the teething probs sorted,, then you can enjoy it!!!

[decobyrne106]

nice one keeneth teathing problems accur might be something completly out of the blue in your case the coils easy fix. seen vids of ye even the car on 3 cyl was going well! struggling but well! hope to see you the next time on full tilt :o

[kenneth]

cheers lads.
the engine i was originally using was a 1600 ford x-flow. about 120bhp

hopefully once i get some issues sorted i'll be able to give it plenty of abuse.

could someone tell me is a screamer pipe of any advantage as i like the sound of it but no idea is it worth doing??

[marksull]

would u sell the x flow? is that garage cooneys in coachford buy any chance? from coachford myself, brother has a white mk2, u might know it?

[richy180]

different build this, ,hope all work out good and u get evrithing sorted to perfection :)

[kenneth]

would u sell the x flow? is that garage cooneys in coachford buy any chance? from coachford myself, brother has a white mk2, u might know it?

not selling the x-flow as have another escort for that engine
yep thats cooneys.
think i know your brothers car alright but dont think i know him.
it's arched is it ??

this is the one i drive around on the road maybe you might have seen it.


http://i197.photobucket.com/albums/aa112/kennethsewell/my%20escort/file.jpg

[kenneth]

right so the gearbox spits oil up the gear lever so i took it out and this is what is there.
is there a rubber missing or something???


http://i197.photobucket.com/albums/aa112/kennethsewell/file-4.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/file-5.jpg

[driftescort]

Is there a rubber boot attached to the gear lever you took off?

[kenneth]

No rubber anywhere there.

[Prodrifter86]

Cool build.. a work friend of mine is building a 3 door sr powered mk2 at the min... aswel. shud be class! i also have a shed full of group 4 parts if you want anything let me no

[kenneth]

cool lad is that josh by any chance.
ya i'd be interest in the grp4 stuff sure pm me what you got and prices.

well today i got it back firing on all 4 cylinders turned out to be a broken wire from ecu to signal no.4 and also the ignitor was goosed.
thanks to iain for the wiring help & thanks to driftescort i also got the rubber for the gearbox to stop it spitting at me. lol

so hope to get back on track asap and considering doing the Rosebowl Cup next Saturday night

[decobyrne106]

there should be a rubber boot around the gear stick to stop the oil

[kenneth]

cheers declan, i got sorted with one from driftescort.

[kenneth]

just looking for some advise lads,

is this extra capacity baffled sump worth having on a car purely used for track ??

http://www.japspeed.ie/Nissan-200SX-S13/Engine-Tuning/Nissan-SR20DET-High-Capacity-Baffled-Sump-Kit/p-2-73-328/

[kenneth]

so just an update on this. it's copied over from irish escort club

this was in mid november....

well today i got it back firing on all 4 cylinders turned out to be a broken wire from ecu to signal no.4 and also the ignitor was goosed.
thanks to iain sutton for the wiring help & thanks to driftescort i also got the rubber for the gearbox to stop it spitting at me. lol


well here is the wire that caused all my problems

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20120930_134707.jpg



so have a few jobs i want to finish out this yoke.
firstly was to get new cosworth frontt discs as the last set i got where warped.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20121011_202708.jpg

i want to change my front springs from 250lbs to 350lbs so Iain Sutton had these for me

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20121111_194317-1.jpg



and a random photo i found :D


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-65.jpg

[kenneth]

this update is from 28th december

little or no progress on this lately :cry:

but today i went with whitedog to crannagh to see how his car is coming on.
so i stuck my bonnet in the back of the tranny to hopefully have rob do some louvres.

fair play to Rob he let me work away with the louvre tool and between me, whitedog and christie this is what we did.

to say i'm pleased is an understatement and this should really help with keeping the temps under the bonnet down alot more as this drifter gets seriously hot.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20121228_184330.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20121228_184344.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20121228_184356.jpg

[gem-s13]

Wel lad just had a quivk flick over the build there. I did a bit of work on the 180 you got the engine out of. The air flow meter is to close to the turbo ware you have it try get it further away and have a bend or 2 in the pipe will make it smoother comeing on and off boost

[kenneth]

cheers lad i'll try something with it alright going to take it WCP just to check the map and make sure its running correct.

[gem-s13]

From what i remeber it was 300bhp the last time was mapped it only on stock injectors and an rb26 afm. but the turbo was changed since and it went i think

[kenneth]

yeah the turbo was a bit smokey so i got a absolute mint one from RFinn and fitted that.
the printout i found in the car said 303bhp.
i'd like it to have 350bhp just for the sake of it so whatever John in WCP recommends thats the plan.

but honestly the power it has is a real laugh in such a light car any day i was out i reckon it has enough.

[kenneth]

an update from the start of February....

well was out today in the 4dr making sure all was well.

i had a feeling that the head was blown as the dreaded mayonnaise was on the dipstick and oil cap earlier in the week.
so i drained out the coolant and it looked good. then compression tested the engine and got 145psi across all cylinders.
the engine also would sit at 84 degree.

so now after driving the oil no longer has the mayo so it could be possible that since it hasnt been driven properly since september that it could have been just moisture in the engine from not using it.
well lets hope so :D

and just when i was all happy, the f**ker decided to blow up some halfshafts.
the english axle obviously wasn't built to take 300bhp :o
i have 6 sets of halfshafts but i reckon i will need to do something about making it stronger.
the worrying thing is that i wasn't even pushing the car when it gave up.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-67.jpg

i got the diff out of the car and this is the piece left in it.
i cleaned out the diff of all the pieces & fitted another set of shafts

but it's breaking shafts easily when its not even drifting so after a call to Declan Munnelly, John Moynihan, Donal Healy motorsport & Camillus Bradley it looks like an Atlas is the way forward.

so plan would be a shortened atlas to maybe 47" or 48"
2 pieces 18 spline shafts
and a gripper lsd with 18 spline side gears.

obviously this is all expensive so this will not happen overnight,
so i have 7 more english shafts and start saving for the bits to build me a bomb proof atlas.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file-68.jpg

[kenneth]

from mid february....


so yesterday was up in Crannagh with whitedog and on the way home it would be rude not to call into Gary Gallagher.
so i just picked up some small bits
got LSD oil for my 2dr as i have a new Gripper diff bought for that.
and i got fibreglass bumpers for this car.

so i fitted the rear bumper today and when i went to fit the front i realised the intercooler pipework is in the way of the original mounting points so i will have to come up with another mounting point. i might just tack a diy bracket to the body or something

also back out testing today and all was good. no broken shafts this time but i was nursing to be honest and just making sure all things are ok.
so temps are good at 82 will driving around and 85 with fans while pushing.
the rear arches will need to be rolled over more just to stop the rubbing.
and the welded is a fucking mare on the road ! 3rd gear bring on power and boost then she breaks traction and trys to go sideways which is a bit scary :D
so will be track testing hopefully later in the week to see how it is drifting now it's back on full power :up:




http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps25abe695.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps26f839fd.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps88e9afda.jpg

[kenneth]

and this is now up to date.

so i just took delivery of my new axle setup.
it's a Gripper LSD with 18 tooth side gears, and a pair of 18 tooth halfshafts.
John Moynihan supplied all the bits and put it all together for me.

you can see the shaft size difference in one picture below.

so should have it all fitted tomorrow night and get some testing done



http://i197.photobucket.com/albums/aa112/kennethsewell/20130306_172739_zps6618d072.jpg


http://i197.photobucket.com/albums/aa112/kennethsewell/20130306_165607_zps7f06fd52.jpg


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsa24b4b56.jpg


Also got my copy of Retroford in the post and was over the moon to see my 4dr in it.


http://i197.photobucket.com/albums/aa112/kennethsewell/20130306_175019_zps0bf20001.jpg

[paulshox]

always loved mk2's like every other petrol head i suppose! looks unreal keep up the good work

[kenneth]

thanks lad.

small update...

took the car out for a spin to see what my new John Moynihan axle was like.....

the main this is it didnt break but it did spit out the lowering blocks so another job to sort might make some welded in blocks for it.

also found my nissan fuel tank leaking around where the pump fits in so need to sort that too.
would anyone have the rubber ring that seals here that they could post to me i could cover cost on paypal ??



http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps0eb9c52a.jpg

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps67541888.jpg

[kenneth]

here is an update of the last few weeks.






So with Retrostock not too far away i have been getting to all the jobs that need finishing.

firstly i dropped it over to Donal Healy to go through all the suspension and set it up correctly.
he found that my alloy rack extensions where shit only after 2 outings so he made me new steel steering tierods which will be much safer.
he found plenty lose and the rear axle was way out of position and adjusted my antiroll bar correctly.
he then set my castor and camber.
once i got to go drive the car it has made a huge difference to the handling and i'm very happy with the job done. :up:
and i got a free sticker :D

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps09ec3289.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps09ec3289.jpg.html)



then the car was brought straight to Dion's to have the whole lot of the wiring tidied up and a new switch panel built.
had a fuse panel mounted to the panel along with all the other necessary stuff.

the view from the cockpit.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20130427_142706_zps6ebee047.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/20130427_142706_zps6ebee047.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20130427_142713_zpsb3fbc762.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/20130427_142713_zpsb3fbc762.jpg.html)


and took a pic out in the yard after been allowed do a few figure 8's

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20130427_123141_zpsa302ae05.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/20130427_123141_zpsa302ae05.jpg.html)



made a small video doing a burnout once i got home :D :burnout:

http://youtu.be/e-i1FuhG4I0



also i have cooling issues once the car is driven hard so Davidc in Classic and Rally Spares sorted be out with the safari spec triple cored radiator, so this should be fitted this week but it will need some tweeks to fit with the sr20 engine.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps14b10e4a.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps14b10e4a.jpg.html)

[kenneth]

so the new rad dont really fit so i had a few changes made it
very tight for space now so trying to find a very slim fan as i only have 40mm space at the bottom of the rad

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps224b4e1b.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps224b4e1b.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsfe4f05c2.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsfe4f05c2.jpg.html)

here is a piece of stainless made up to sort the severe angles for the coolant and the a pic of it all finished fitted.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsf647f9b5.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsf647f9b5.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps254004e2.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps254004e2.jpg.html)

so this weekend was spent finishing off the car for RetroStock next week.

i fitted some checker plate to the floors to tidy it up and put in an old passenger foot brace we found.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps3905447e.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps3905447e.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpse3e23b0b.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpse3e23b0b.jpg.html)



i got some out of date 6 points from John Moynihan and Vince welded in some cage pipe to mount these off.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps65dcfa1f.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps65dcfa1f.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsc599880a.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsc599880a.jpg.html)



also filled in around the intercooler and added some flared holes to let air at the intake.
the intercooler is now painted black and i think it looks better


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsec4bce73.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsec4bce73.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps2e0b1b03.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps2e0b1b03.jpg.html)



so thats it really. she's pretty much ready to get abuse out on track

:burnout: :burnout:

[kenneth]

so just before Retrostock i decided that i had to have some shark teeth on the car so whitedog did the most of this as my patience for this kind of masking, painting & more masking is non existant :D


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps727ef7af.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps727ef7af.jpg.html)


so drove the car plenty but on tuesday before Retrostock she stopped reving above 4000rpm while driving so got loads of varying opinions on what it could be.
so i began with getting a new performance fuel pump & straight away problem solved.
but i was a little worried about it in case it was now leaning which could blow the engine so i booked into WCP Dyno in castleisland for friday morning.
John was a real helpful guy with plenty solid advise and didnt try to bullshit me as i explained i had no experience what so ever with these jap engines.

the dyno through up a few problems,
1. turbo actuator was leaking boost so would not allow it to make full power.
2. when all mapped up the ECU would not save it as it needs some relay to allow a 12v zap to memorise. this isn't an issue until i need it mapped again in future.
3. i need to move the air intake as it's taking hot air from behind the rad. when we fed it cold air with a fan it made another 17bhp :o

so my final figure was 235bhp due to the actuator. with this sorted it will hold boost proper, a relocation of air intake and ECU relay added in, it should make about 280 to 300bhp.

even with 235bhp it felt awesome on track so still very happy.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps92b0dbed.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps92b0dbed.jpg.html)


a stack of tyres for some shredding

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps336c52a2.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps336c52a2.jpg.html)


and after :D


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsceff7a97.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsceff7a97.jpg.html)


so about 3pm myself and Dec (9928zk) where out and as they say "he ran out of talent" and i put it into the earth bank with the rear and the front came round and bent that too and broke the steering rack.
so they moved the car off track and that was my day over.


front i pulled out pretty easy.

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps356d827a.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps356d827a.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps0a951a74.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps0a951a74.jpg.html)


and some few pics from on track.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps7bee0666.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps7bee0666.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpscf9333ce.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpscf9333ce.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps8b44b406.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps8b44b406.jpg.html)

[NissanSilviaLover]

beautiful mk2 m8

[migdiffs]

good work:cool:

[mike e30]

class lookin mk2 man. How did u find retro stock hoping to make the next one in September

[kenneth]

so i haven't updated this in over a year..
this is mostly what went on.

JULY '13
Last weekend i took the car out to the RallyConnection Track in Dungarvan.
The Slowly Sideways Ireland group had booked the track for the day and inc a BBQ.

so firstly i took the car to Mike Deane (as he is well up on sr20's) to have an ECU wiring issue sorted, the oil breather was filling the oil catch can and an overheating issue, & sorting the geometry after hitting the earth bank in Mondello.
Fair play to Mike he solved all these :up:

so collected it of Mike on saturday morning and straight out to the track.
it was a class day and savage weather the heat was nearly too much as we had to wear racesuits.
it was cool getting out on laps with the likes of Metro 6r4, Ex Mcrae Legacy, Quattro, Alpine to name a few Group B's

Me, Brian, Jason & Denis were the only 3 escorts there so we had to show these group B's how it's done :rofl:

i had one incident where i hit a bank in the rear quarter after the legacy shot through the wrong way a came my direction..... i was raging and launched int the next corner. not much damage done as it was the same panel as the one i smacked in Mondello.

so here are some pics....


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps807a55ee.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps807a55ee.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps23539086.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps23539086.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsbd38546a.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsbd38546a.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpse0244696.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpse0244696.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps2ab67ee0.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps2ab67ee0.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps2e8a47ae.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps2e8a47ae.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsad9ef2ac.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsad9ef2ac.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps84ef08f4.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps84ef08f4.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsa58e70dd.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsa58e70dd.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps08282d76.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps08282d76.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsf1b847fc.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsf1b847fc.jpg.html)



and i nearly rolled the car at one stage, the photographer said at one point 3 wheels where off the ground :o :o


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsecd88088.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsecd88088.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsa62675a3.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsa62675a3.jpg.html)

[kenneth]

SEPT '13

just doing some preparations for Retrostock.

firstly i'm fixing the dent which has been smacked twice at this stage :D


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/20130706_181551_zps9cfbe230.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/20130706_181551_zps9cfbe230.jpg.html)


managed to get it out roughly to this.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps7febbac5.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps7febbac5.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsa38d6afb.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsa38d6afb.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps98389e42.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps98389e42.jpg.html)


next i got the CS engineering extra lock kit which simply bolts into the rally design steering racks. Davidc in Classic & Rally Spares sent me down a new rack and i stripped it straight away :D

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps9ae50f03.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps9ae50f03.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps401b18a8.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps401b18a8.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsd9d6f947.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsd9d6f947.jpg.html)


also the plan is to go back to 13" wheels so i need to make a new brake conversion that work with 13's as the setup i use at the moment only works with 15's
more on this tomorrow :up:

[kenneth]

SEPT '13

so finally back on 13" wheels.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps959af99b.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps959af99b.jpg.html)


and have the tyres sorted just waiting for some more wheels now :up:


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsf65237ab.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsf65237ab.jpg.html)

[kenneth]

some photos from retrostock

Thanks lads
some photos from Retrostock.


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/Autolifers_Martin_RetroStock_2_0017_zps7805baeb.jp g (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/Autolifers_Martin_RetroStock_2_0017_zps7805baeb.jp g.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/Autolifers_Martin_RetroStock_2_0479_zpsd1343442.jp g (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/Autolifers_Martin_RetroStock_2_0479_zpsd1343442.jp g.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/870_zps346637e9.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/870_zps346637e9.jpg.html)


twin battle of the 4drs :D

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/1239891_528564693892647_1984355472_n_zps3f61bff4.j pg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/1239891_528564693892647_1984355472_n_zps3f61bff4.j pg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/1238017_384958858299151_1835384980_n_zpsebf7c809.j pg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/1238017_384958858299151_1835384980_n_zpsebf7c809.j pg.html)


these last too show the new amount of lock i have now. very happy with it :up:


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/993421_614122108639318_1805375378_n_zpsdea69651.jp g (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/993421_614122108639318_1805375378_n_zpsdea69651.jp g.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/996625_10151922649443103_1854668778_n_zps644a24b6. jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/996625_10151922649443103_1854668778_n_zps644a24b6. jpg.html)

[kenneth]

JAN '14

here is a clip from the morning track session i organised for Kartworld in watergrasshill.


<iframe width="853" height="480" src="//www.youtube.com/embed/ZAbWjOcbyC8" frameborder="0" allowfullscreen></iframe>




as you can see from the video i still have overheating issues :frustration:
so everything possible is checked so i have narrowed it down to 3 things which i am gonna try an solve asap
1. a remap as it's lean high up the rev range which will make it run very hot
2. more airflow into rad... basically a bigger hole in the front panel :D
3. the pipe for the top hose was made in a panic and has 4 x 90degree bends which might slow water flow down so gonna reweld the rad outlet so only 1 90degree is needed.


here is the extra i'm cutting out this should create a 2.5" funnel of air direct into the rad

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsf588279f.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsf588279f.jpg.html)





Also i won a facebook competition run by OBP Motorsport :D
the prize was a new PRO-RACE floor mount pedal box worth €444 so thats also gonna get fitted


http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zpsbfe9169c.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zpsbfe9169c.jpg.html)

http://i197.photobucket.com/albums/aa112/kennethsewell/mk2%204dr/file_zps5f387a22.jpg (http://s197.photobucket.com/user/kennethsewell/media/mk2%204dr/file_zps5f387a22.jpg.html)

[kenneth]

so thats pretty much up to date changed jobs so '14 meant i didnt get any time in the car.
i took it out 3 wks ago to rallyconnection and blew the engine so am on the look out for a replacement or a very good bottom end

[grange]

Fairplay man only seen this now its as fuck