Team Kanjiuma 2011 Nissan Silvia S15 (built by Calicages Racing)

Well lads/lassies,

Team Kanjiuma in association with Calicages Racing/mod doctor have decided to share our build of the 2011 Nissan Silvia S15 drift car. This build will show the lesser experienced people on the site how to build a pro car to the highest standards within our budget for 2011. We welcome your questions / queries and for the more experienced guys we welcome your comments or possible improvements you could suggest to the build.

Update 1.......19/11/10.

Below is a 2001 Silvia which competed in the 2009 Prodrift season, it was driven by myself and is in need of a re-fresh.


http://i1188.photobucket.com/albums/.../121110071.jpg

Ok so Day 1 we rolled in S15 on the very handy costume made Dolly frame. If you have small garages with a few lads working out of same this is a handy tool. We can move car shells in and out of garage within ten minutes.

http://i1188.photobucket.com/albums/.../121110072.jpg

http://i1188.photobucket.com/albums/.../121110073.jpg

Above is the S15 stripped of its dash/engine etc, as you can see the standard loom is very bulky and 70% of it is not even required to run drift car. We will be reducing the loom to the bare essentials; the advantages of this are weight reduction and less of a chance of car going on fire due to excessive unnecessary wires.

http://i1188.photobucket.com/albums/.../121110082.jpg

When removing loom we label every plug to the best of our ability to simplify the striping down of the loom at a later stage. I know nothing about wiring so I am lucky that Stiv (Mod Doctor) and Nelly are experts.

As you can appreciate this project build will be slow as we all work during the day but the Prodrift dead line 2011 has to be achieved.

P.S. Yes I know there is another thread started by Mark about this build be he seams to have lost interest in the S15 up dates…fecker is only up dating his own one…so that’s why I started fresh.

Update 2.....20/11/10

http://i1188.photobucket.com/albums/.../121110074.jpg

Unfortunately the back of the S15 was damaged; this obviously wouldn’t be the most ideal shell in the world be we all have budgets to abide by. Nelly got to works see below.

http://i1188.photobucket.com/albums/.../121110086.jpg


I suggested a localised repair in the damaged area but Nelly was insistent of a full panel replacement. This involved drilling out of all the spot welds and removal of side and back window.


http://i1188.photobucket.com/albums/.../121110077.jpg


http://i1188.photobucket.com/albums/.../121110080.jpg


http://i1188.photobucket.com/albums/.../121110082.jpg

This is gona be a brilliant thread.... especially for people like me who know f**k all but want to know more about the work that needs to be done to get a car to top standard..... best of luck with it.. Il stay tuned in anyway

Looks good Don.

good to see more s15's been used we need to get some baller status goin with the s15's

As jimmy said good to see more s15s been used in the drift scene.. Best of luck wit the build.

Update 3.......22/11/10.

Yesterday we commenced work on a new idea (well it’s probably an old idea but new to us anyway). Over the past few years I seamed to be having problems with cracking of manifolds, this arose from three major problems, drift car having larger exhaust and it being lowered down to the ground hence exhausts banging of the ground and these shocks causing cracks in manifold. The third reason is that I didn’t have a flexi exhaust section fitted after the turbo exhaust pipe to absorber any shocks that may come up from the latter part of the exhaust hitting the ground.
As seen below where the flame is, Nissan have allowed room in the passenger foot well for the standard silencer box, we have decided to extend this all the way to the front of the car,the second picture shows the sloping of the tunnel up upwards this allows smoother bends for the down pipe. This also keeps the leading elbow on the bottom part of the exhaust up off the road saving the manifold.


http://i1188.photobucket.com/albums/.../121110087.jpg


http://i1188.photobucket.com/albums/.../121110088.jpg

Quote:

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Originally Posted by Doofer

This is gona be a brilliant thread.... especially for people like me who know f**k all but want to know more about the work that needs to be done to get a car to top standard..... best of luck with it.. Il stay tuned in anyway

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I agree Cheers lad

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Originally Posted by docco86

As jimmy said good to see more s15s been used in the drift scene.. Best of luck wit the build.

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Cheers lad...I hope luck is on my side next year.

nice work don :D:D

looking good, say it be ROASTING in the car now :D
ya mite well put a huge air event on the roof :D
tell nelly to hurry up :P:P

podge waants his 180 going;P

Quote:

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Originally Posted by Daraghs14a

Looks good Don.

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Cheers Daragh.

gona be a monster lad,,

Don't blow another box at the top of the track in Portlaoise again please :p
This is gonna be a really cool thread/car :D
Looking forward to the end result :cool:

looking good sofar :D

Quote:

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Originally Posted by S14a johno

nice work don :D:D

looking good, say it be ROASTING in the car now :D
ya mite well put a huge air event on the roof :D
tell nelly to hurry up :P:P

podge waants his 180 going;P

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Ha Ha, rosting for sure...if Nelly gave up the fags she would be long finished.

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Originally Posted by yowdy

gona be a monster lad,,

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“Monster” yes hopefully....but even more needs to be reliable this year.

pm me ur number lad wana ask ya bout few tngs;)

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Originally Posted by Team Kanjiuma (Donjuan)

Ha Ha, rosting for sure...if Nelly gave up the fags she would be long finished.

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nelly ar what he does best.ha:D
http://i480.photobucket.com/albums/r...rs15/004-1.jpg

does nelly ever not have a fag hangin on the lip haha some man gointa be some machine looking forward to it

Quote:

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Originally Posted by Aidan Hogan

Don't blow another box at the top of the track in Portlaoise again please :p
This is gonna be a really cool thread/car :D
Looking forward to the end result :cool:

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That shouldnt happen again....5 speed dog box next year (good for 600bhp so they say). I will fill you in later about it...

Quote:

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Originally Posted by ali-d1936

looking good sofar :D

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cheers lad.

Quote:

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Originally Posted by Team Kanjiuma (Donjuan)

That shouldnt happen again....5 speed dog box next year (good for 600bhp so they say). I will fill you in later about it...

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Thank god ha heavy aul cars :eek:
Looking forward to it smoking Portlaoise out of it again :cool:

Update 4.......26/11/10.


As most of us are aware drift cars need larger tubs for our big 17” + 18” wheels to turn full standard lock and in some cases beyond that. To allow this to occur we need to enlarge our tubs. This can be done a number of different ways, using a sledge/hammer to move back panels that are catching the wheels or reshaping tubs using new steel as seen below. The latter option is probably better but we all have budgets, we started by cutting out standard tubes and installing modified ones. Note that we didn’t go mad cutting shock turrets as it’s advisable to leave as much in place until modified bits are in place.


http://i1188.photobucket.com/albums/.../121110081.jpg


See below the triangular piece on the flat in blue, that’s to leave room for intercooler pipes. It takes great patience to mark out metal but its all worth while when completed.


http://i1188.photobucket.com/albums/.../121110092.jpg


http://i1188.photobucket.com/albums/.../121110090.jpg


http://i1188.photobucket.com/albums/.../121110094.jpg


Some people reckon That this modification may weaken the car, I agree but sacrifices have to be made and some risks have to be taken


http://i1188.photobucket.com/albums/...n/61110003.jpg

Small bit more welding and infilling to be done but this will do for now.

Love these sort of build threads :)

But am I seeing properly, gas welding?? Would have thought with this much effort going into it MIG would have been the obvious choice

Quote:

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Originally Posted by Kav gts-t

Love these sort of build threads :)

But am I seeing properly, gas welding?? Would have thought with this much effort going into it MIG would have been the obvious choice

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Yes that’s gas welding, MIG welder is on loan at the minute so the gas welding will have to suffice. Saying that tho the gas welding is working out pretty well as its great for filling any gaps which have been created by minor errors in fabrication of panels. The gas welding does create a lot of heat and warping of lighter sheets car occur. It’s also working out a lot faster than MIG as MIG is prone to burning holes. Will definitely have MIG for seam welding shell.

Point to note: None of us are full time welders.....

Good work lads be good to see the outcome of this...! Not trying to tell yas what to do or nething but would you consider bringing the cage trough the bulkhead onto the back of rhe original tubs...!


I did this on my own as i was advised to do it by a few top lads...! Supposed to be a great job...!

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Originally Posted by Robbie Daly Ps13

Good work lads be good to see the outcome of this...! Not trying to tell yas what to do or nething but would you consider bringing the cage trough the bulkhead onto the back of rhe original tubs...!


I did this on my own as i was advised to do it by a few top lads...! Supposed to be a great job...!

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Yes that’s defo the way to go for sure, we were discussing this only a few days ago....will defo give extra strength to the front end of car.

We will just have to see how we are getting on with time..cheers for that tho.

..

Quote:

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Originally Posted by Kav gts-t

Love these sort of build threads :)

But am I seeing properly, gas welding?? Would have thought with this much effort going into it MIG would have been the obvious choice

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Ya as don said it's gas welding all the way at the moment. I find it much easier and a lot quicker to weld with the gas but that's what I'm used to I suppose.
Again the only drawback with the gas is with the amount of heat it puts into the metal it can warp it like crazy:mad:

And enough with the pic's of me smoking! I only get a 5 minute break all night lol:D

Update 5.......01/12/10.

We allowed two openings into the cock pit to suit the SR20 gearbox and the shorter RB25 box; the S15 will be fitted with a PPG 5speed dog engagement gear set (straight cut gears) in a standard SR20 gear box casing. If anything happens to the dog box we can revert back to the reliable RB25 box.


http://www.youtube.com/watch?v=-fA94Sxiu4c

http://www.youtube.com/watch?v=IUQiL...eature=related

http://www.youtube.com/watch?v=qekD_PqA02M

http://www.youtube.com/watch?v=n_1jO64tuQA


Few links for anyone who is interested in knowing about PPG gear boxes.



http://i1188.photobucket.com/albums/...n/61110013.jpg

I hope the holes are in the right place.

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Update 6.......03/12/10.

Unfortunately the SR20 gear box is unreliable when the power is turned up on the SR 20 engine so a lot of us install the RB25 gear box. This box is larger than SR one and its advisable to enlarge silvia tunnel to suit. We decided on increasing it by a considerable amount, this allows adequate working space for installation of RB box.

http://i1188.photobucket.com/albums/...n/61110007.jpg

Above roughly shows how the pieces go together.

http://i1188.photobucket.com/albums/...1122010819.jpg

Looking a bit off square but its just the way the photo was taken. Its quite difficult to match a flat piece of steel onto an oddly shaped bulk head but when painted all will be looking good.

http://i1188.photobucket.com/albums/...1112010813.jpg

http://i1188.photobucket.com/albums/...61110012-1.jpg

Not bad for a partimer.

http://i1188.photobucket.com/albums/...1122010820.jpg

Few small pieces to tidy up.

Nice work don and co.

ya may shortly employ nelly full time horse,never mind em been a partimer....sweet work as always doh

jes nelly is well handy wit da gas welding!!! really turning out sweet!!

Jeez Nelly's handy!

Good job lads!

ahh nelly always a dab hand with a welder i seen cages he welded with an arc welder and there serious job woulnt do better with a mig hes more talented than he gets credit for

Cheers Lads for your comments, yes it’s a proven point that Nelly is a competent welder and has been for many years, I guess its good to get it out there.:)

Update 7.......09/12/10.

Team Discussions about re positioning SR20 closer to the centre of the car.


We discussed moving the SR 20 engine closer to the centre of the S15 for better weight distribution. It’s always advisable to position the engine/gearbox (heaviest components) nearer to the centre of the vehicle if possible. This will reduce the vehicle's moment of inertia and makes it easier and faster to turn the vehicle to a new direction. Mounting the engine in towards the middle instead of the front of the vehicle puts more weight over the rear tires so they have more traction and provide more assistance to the front tires in braking the vehicle. As a result, vehicle stability, traction is naturally improved when turning, braking, and accelerating.

To achieve this we would have had to dry sump engine, new engine mounts etc. At this late stage we decided to cancel this idea as it obviously involves a lot of work.

Instead to balance the weight distribution a bit better over the S15 we decided to position the driver further back than normal. This would involve a few minor modifications....installation of paddle box and extension of gear stick/steering wheel.


http://i1188.photobucket.com/albums/...5122010821.jpg


Above shows the blanking of the standard opes for the clutch/brake servos. We did not weld blank plates in place just encase we require them at a later stage if pedal box didn’t work out.


http://i1188.photobucket.com/albums/...5122010822.jpg


From reading the article below it seems Nigel Colfer is running similar pedal box so they must be a good buy.

http://www.the-mia.com/Pro-Drift-Top...-OBP-Pedal-Box

Learn some more about obp pedal boxes.

http://www.obpltd.com/

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Good thinking lad...... Im putting 1 of these in my own yoke there a great job.....! Did you get the cylinders with it....! Pm me the cost please will ya....!

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Originally Posted by Robbie Daly Ps13

Good thinking lad...... Im putting 1 of these in my own yoke there a great job.....! Did you get the cylinders with it....! Pm me the cost please will ya....!

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Good to hear there a great job, yes I got cylinders/ reservoirs with them. Be careful when purchasing because there are many different types. I got the one that mounts on a flat surface but if you have long legs you might need the one that mounts on the sloped part of the foot well. Mark got one type and I got the other. I PM you price.

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i notice the throttle peddle is much bigger than the brake!!:D:D....hardly going to be dogged!!....go on son:D

Thanks 4 the pms lads....! I like the think outside the box approch on this build....! I reckon them pedel boxes are the job 4 left foor braking and also the little bit of toe heel.....! Keep up the good work lads top job...!

Quote:

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Originally Posted by Robbie Daly Ps13

Thanks 4 the pms lads....! I like the think outside the box approch on this build....! I reckon them pedel boxes are the job 4 left foor braking and also the little bit of toe heel.....! Keep up the good work lads top job...!

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Yeah sure robbie.......the only heel toe action you'l be doing will be in a homosexual line dance @ 5 in the mornin!!:p:p