Andrew's '93 NA6 - KL V6 swap

zossy1 · Postby **zossy1** » Wed Jul 18, 2012 6:27 pm

Those abrasive discs I linked come in two kinds - brown (very abrasive - for doing cast iron blocks, etc) and blue (less abrasive - for doing alloy castings like cylinder heads).

Unless you are completely ham-fisted, you can't wear any facing material away with these. If you have ever seen one you will understand why - they are made of nylon-type material, kind of like a scotch brite pad. In fact, I would argue that using a razor blade is more risky. Especially when working with alloys, it is absolutely possible to gouge the surface with the blade if you attack it too aggressively.

Add to this, shaving a cylinder head with a razor blade, and doing it properly, can take a LONG time and a lot of effort. I have done a nasty, dirty head with one of those discs, and had it looking like new, in less than 5 minutes.

RedMX · Postby **RedMX** » Mon Jul 23, 2012 2:50 am

Found this image, dunno if its much use........ but its pretty to look at.
Dunno how hard it would be to do a plug change :roll:

mitch_f1 · Postby **mitch_f1** » Mon Jul 23, 2012 9:50 am

Mann, ITB's on a KL would sound THE SEX!!

Beelzeboss · Postby **Beelzeboss** » Mon Jul 23, 2012 11:05 am

RedMX wrote:Found this image, dunno if its much use........ but its pretty to look at.
Dunno how hard it would be to do a plug change

That looks like an awesome setup, it even looks like it would fit under the bonnet

something to consider upgrading down the track. I really wanted a supercharger but I don't want to have to upgrade the gearbox so I think it will stay N/A. Once it's registered I'm thinking of getting a set of upgraded cams, though I feel the first thing I should upgrade is the exhaust manifold which is annoying because there really is no space at all for a decent set of extractors.

I was up until 1:30 getting the engine back together, it looks like the car will drive tomorrow

All that's left is to tweak the tune a bit so it runs properly. I'm going to try and get a permit to drive to a few places so I can tune it on the road.

mitch_f1 wrote:Mann, ITB's on a KL would sound THE SEX!!

It sure would, I love that video of the blue MX-5 with the KL on ITB's, such a great sound.

PaulF · Postby **PaulF** » Mon Jul 23, 2012 4:18 pm

I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters... :lol:

RedMX · Postby **RedMX** » Mon Jul 23, 2012 11:53 pm

PaulF wrote:I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

I don't think it would be too hard to box them up as they sit now. :shock:

No real different to the Mazdaspeed B6 ITB cover/intake except having the pods in there too.

ampz · Postby **ampz** » Tue Jul 24, 2012 10:40 am

Not sure if it's already been covered here, but the Vitara V6 share the same block, granted the engines are chain drive vs belt but at a guess maybe the intake manifolds fit the port spacings?

There's a place called suzifour spares in St Marys, might be worth taking your spare manifold to check it out.
I've seriously been looking at a similar mod to my NA6, but using the Suzuki version of the KL, it already has the FR orientation and COP standard. The weakness of the timing chain tensioners is what is putting me off the conversion.

bruce · Postby **bruce** » Tue Jul 24, 2012 2:23 pm

PaulF wrote:I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

He would be thinking SIX filters? Oh, it's a six cylinder...!

Beelzeboss · Postby **Beelzeboss** » Tue Aug 07, 2012 7:36 pm

Thanks for the comments everyone

PaulF wrote:I'm just imagining a HWP officer opening your bonnet to find SIX exposed pod filters...

they'd have a field day, the way they go on about the dangers of pod filters.

ampz wrote:

Not sure if it's already been covered here, but the Vitara V6 share the same block, granted the engines are chain drive vs belt but at a guess maybe the intake manifolds fit the port spacings?

There's a place called suzifour spares in St Marys, might be worth taking your spare manifold to check it out.
I've seriously been looking at a similar mod to my NA6, but using the Suzuki version of the KL, it already has the FR orientation and COP standard. The weakness of the timing chain tensioners is what is putting me off the conversion.

Thanks ampz, I don't have a spare manifold though, both the ones I have are in pieces. I'm fairly sure I'll supercharge it at some point down the road so I don't think I need yet another N/A manifold.

It's been a while since my last update and a lot has happened. The car isn't registered yet because I've had an issue with the remote oil filter. The line popped off from the pressure. Luckily I shut the engine off about half a second after it happened so I'm confident there's been no damage but I'm remaking the entire system to take a cheap/large Z9 filter (Commodore V8, Falcon, etc.) and using braided AN-10 lines. This is one area where I don't want to have a failure so I'm going all out to ensure reliability. I'm also going to put in an RX-7 oil cooler across the front of the car.
I have a 1 week break from uni in about 3 weeks so I'm hoping to get it finished then, but it very well may take until November before it's registered. 2nd semester 3rd year mechanical engineering is really time consuming

Beelzeboss · Postby **Beelzeboss** » Fri Aug 17, 2012 3:10 pm

I've been pretty busy with uni lately but I have managed to do a bit on the new remote filter setup. I'm using a Z9 filter which is massive compared to the original, it's used on Holden 5.0's and a few other big engines. They're cheaper than standard MX-5 filters, too.

^ Ignore that drawing, I've changed it from an NPT thread to an external -10AN thread to make the whole thing shorter and eliminate a point where it could leak.

I've done a bit more but my camera battery went flat. Yesterday all the braided stainless hoses and AN fittings arrived from Summit so with any luck I'll have it plumbed in and running by the end of this weekend.

I also did a bit of wiring for the tacho. It needs a pullup resistor for the adaptronic so instead of wiring it in externally I made a simple resistor with crimped terminals which bolts on to the back of the cluster. It works perfectly so far and is easily removeable.

By the end of today I hope to have the filter side of the oil filter relocation kit finished, tomorrow I'll work on the engine side which should be much less complicated.
I decided to make my own because I wanted to use 3/4" NPT threads because I already have that tap. It's also the size I'll use for the -12 dry sump scavenge line.

Also I've booked in to see an engineer in a few weeks.

Beelzeboss · Postby **Beelzeboss** » Fri Aug 17, 2012 10:24 pm

Well I didn't get it quite finished tonight but it's close. I just have to weld on a piece to the central shaft and drill a few holes to secure it to the outside housing.

As always comments, questions and criticism welcome.

username · Postby **username** » Fri Aug 17, 2012 10:52 pm

who could criticize that work? its beautiful!

Beelzeboss · Postby **Beelzeboss** » Sat Aug 18, 2012 10:38 am

Thanks username

plohl · Postby **plohl** » Sat Aug 18, 2012 11:28 am

Looks pretty good dude!!

Was it hard setting the chamfer for the fittings? Or just a bit of forethought

Sent from my GT-I9100T using Tapatalk 2

Beelzeboss · Postby **Beelzeboss** » Sat Aug 18, 2012 8:13 pm

Thanks Plohl, it wasn't too hard to make the AN fitting. I just googled to find they're a 37 degree taper and AN-10 is a 7/8" x 14 TPI thread. I used the cross slide to cut the taper, it's marked for angles so I just set it to 37 degrees and it seems to match up perfectly with the rest of the fittings.

I just finished the oil filter thing, here's a few pics of the finished article.

I bought a huge piece of aluminium from a scrap metal place to make the engine side of the adapter but it's going to have to wait until next weekend. I have a few assignments which take priority but in 2 weeks I have a week off and my appointment with the engineer is on the 8th of September. It has to be pretty well finished by then.