Andrew's '93 NA6 - KL V6 swap

Beelzeboss · Postby **Beelzeboss** » Sat Mar 24, 2012 4:01 pm

When taking the engine out just now Dad didn't do up the chain properly so the engine was dropped on it's nose from about a metre in the air. It absolutely f%&$ed the front crank pulley and also stuffed the alternator. The crankshaft seems OK as the brunt of the impact was taken up by the damper in the pulley. Luckily nobody was hurt and the engine was just out of the car, so no damage there.

I'll take some pics after I've calmed down.

bruce · Postby **bruce** » Sat Mar 24, 2012 4:54 pm

Your dad is sacked.

Pamex · Postby **Pamex** » Sun Mar 25, 2012 9:29 am

Massive condolences. Sorry to hear.

Bizi · Postby **Bizi** » Sun Mar 25, 2012 7:54 pm

Seconding Pamex... OUCH on all counts of engine, egos etc but seriously, safety is your number one priority. Lucky nobody got hurt!

I am so sorry. Hope that you can rescue the situation with some luck and decent suppliers. Temporary setback only...

Beelzeboss · Postby **Beelzeboss** » Sun Mar 25, 2012 9:03 pm

Thanks Pamex, Bizi and Bruce, dad is most definitely sacked.

After examining the engine a bit more the damage doesn't look too bad. The alternator was broken and the main crank pulley was also destroyed. Dad has offered to replace the components and picked up a 2nd hand alternator today. He also bought a new underdrive lightweight pulley from ebay so once that arrives all the damage should be repaired.

Replacement alternator from pick and payless.

Hjt · Postby **Hjt** » Sun Mar 25, 2012 11:35 pm

He should buy you another mx6 invade future mishaps!

I'm posting about your pod filter, you said you plan to box it, are you looking to feed the box from a different location or keep it short? Perhaps you could make a hole in the firewall and run a pipe into the air box?
Just seems a bad place to suck air from..

Beelzeboss · Postby **Beelzeboss** » Sun Apr 01, 2012 7:43 pm

Hjt wrote:He should buy you another mx6 invade future mishaps!

I'm posting about your pod filter, you said you plan to box it, are you looking to feed the box from a different location or keep it short? Perhaps you could make a hole in the firewall and run a pipe into the air box?
Just seems a bad place to suck air from..

I think I'll just have a short intake from the box to start with, that's where the standard MX-5 intake is so it can't be too bad. Maybe once I've got it running and rego'd I'll look into a new intake from the front of the car. I don't really want to bore a hole in the firewall.

The engine is in for hopefully the final time, the exhaust has been modified slightly so it now clears everything, the coolant re-route is finished and the EGR is now completely mounted and plumbed in.

List of things left to do:
Rear section of exhaust
Vacuum fittings (easy)
Hoses
Throttle linkage
Intake (easy)
Coil bracket (easy)
EGR solenoid bracket (easy)

I'm going to order a set of v-band flanges. Until they arrive I'll work on the exhaust from the rear to the front, that way once the flanges arrive it should be simple to join it up.
I'm hoping to have the car finished by easter as I have a break from uni the following week. I want to get the car engineered and rego'd during that week.

Postby **NitroDann** » Sun Apr 01, 2012 8:08 pm

Dont forget to put anti galling paste on th Vband clamps nut, then tighten the clamps together hard before welding, in the correct orientation to make sure they dont warp.

Im serious aboiut the anti galling paste too.

Dann

Beelzeboss · Postby **Beelzeboss** » Tue Apr 03, 2012 6:29 pm

nitrodann wrote:Dont forget to put anti galling paste on th Vband clamps nut, then tighten the clamps together hard before welding, in the correct orientation to make sure they dont warp.

Im serious aboiut the anti galling paste too.

Cheers Dann, I'll definitely do that. I've never used v-band clamps before.

Today I got my MX-6 exhaust system adapted to the MX-5. It was a bit difficult as every component in the system is much bigger than the original.
I put the muffler as a centre exit because it simplified the pipework. The cat and resonator are unmodified, I just had to weld new hangers onto everything and join the rear muffler to the resonator.
Unfortunately I didn't take progress photo's so here are some bad pics of under the car :lol:

I welded some new hangers onto the tow hooks to support the centre exit muffler, they seem to work really well.

And, brace yourself, one of how the muffler looks from the back of the car

I also put in the rear coilovers at the recommended height setting to see how low it would be. The new swaybar isn't connected yet.

Not much clearance under the muffler, it hangs a bit low because it's massive.

Postby **Okibi** » Tue Apr 03, 2012 8:27 pm

Perhaps you could convince your dad to buy you a new muffler as conciliation for dropping the donk. :mrgreen:

Beelzeboss · Postby **Beelzeboss** » Tue Apr 03, 2012 8:34 pm

Okibi wrote:Perhaps you could convince your dad to buy you a new muffler as conciliation for dropping the donk.

I wish! It's not too bad, I've got another muffler but doubt it would pass the noise test so I'm not going to install it.

Bizi · Postby **Bizi** » Tue Apr 03, 2012 9:04 pm

I agree with the compensation suggested.

Nice work getting the KL exhaust to fit and I understand the logic - to get it passed and it is OEM quiet, in theory.

Did you look at other 'KLiata' exhausts?
I only ask because you might get much betterground clearance a different way. Just thinking out loud, pardon the pun.

I don't know if it's helpful but have you looked at what the design is for the VW R32 MkV, in case that design helps (sounds amazing and has the centre outlets).

Like this Milltek design (arquay, kresseig and others are even nicer of course!).

Exhaust porn...
http://www.golfmk5.com/forums/showthread.php?t=108108

mitch_f1 · Postby **mitch_f1** » Tue Apr 03, 2012 10:14 pm

So is that big muffler just for engineering and passing the various tests, then are you putting the other one on?

Beelzeboss · Postby **Beelzeboss** » Tue Apr 03, 2012 10:22 pm

Bizi wrote:I agree with the compensation suggested.

Nice work getting the KL exhaust to fit and I understand the logic - to get it passed and it is OEM quiet, in theory.

Did you look at other 'KLiata' exhausts?
I only ask because you might get much betterground clearance a different way. Just thinking out loud, pardon the pun.

I don't know if it's helpful but have you looked at what the design is for the VW R32 MkV, in case that design helps (sounds amazing and has the centre outlets).

Like this Milltek design (arquay, kresseig and others are even nicer of course!).

Exhaust porn...
http://www.golfmk5.com/forums/showthread.php?t=108108

Thanks Bizi but I'm not keen to spend any more money on the car at the moment, I'll just wind up the coilovers and live with the KL muffler.

mitch_f1 wrote:So is that big muffler just for engineering and passing the various tests, then are you putting the other one on?

Yeah it's for easier engineering. I might change it later depending on how loud the stock exhaust is, it sounded pretty good when I drove the donor car and that had the pipe crushed down to 1/2" wide at one point.

I bought a couple of bullet mufflers a few months ago to add to the stainless system I made, with the oval rear muffler it should make a system which isn't too loud.

Beelzeboss · Postby **Beelzeboss** » Thu Apr 05, 2012 9:48 pm

Today my red vacuum hoses arrived so I decided to make the fittings for the manifold. They're all threaded M10x1.5, I made 2 x 4mm ones for the charcoal cannister and EGR, a 6mm one for the MAP sensor and a 10mm one for the brake booster. I forgot to make another 2mm one for the fuel solenoid, I'll make that tomorrow.

I also put new pipes and fittings on the oil filter relocation setup. It took AGES but it simplifies the hoses and moves them away from the exhaust.