Andrew's '93 NA6 - KL V6 swap

Veloce · Postby **Veloce** » Tue Sep 11, 2012 1:43 pm

Spent many hours on a shaper in the first year of my apprenticeship. Cool machine to work with!
We have a greatb laser cutter here at the school now which is great to use.

Beelzeboss · Postby **Beelzeboss** » Thu Sep 13, 2012 12:32 am

Thanks MrPham, Gladiator and Veloce

The shaper is great, I haven't used it much before but it's great fun to watch working, mesmerising.
Having access to a laser cutter would be fantastic. I can use a few machines at TAFE but they're mostly for sheet metal working.

taminga16 · Postby **taminga16** » Thu Sep 13, 2012 12:41 am

Beelzeboss wrote:Thanks MrPham, Gladiator and Veloce

The shaper is great, I haven't used it much before but it's great fun to watch working, mesmerising.
Having access to a laser cutter would be fantastic. I can use a few machines at TAFE but they're mostly for sheet metal working.

When I was at school 40 years ago, it was the machine voted most to draw one into touching it during operation. Not that I would recommend it though.
Greg.

bruce · Postby **bruce** » Sat Nov 24, 2012 11:50 am

Any progress?

Beelzeboss · Postby **Beelzeboss** » Sat Nov 24, 2012 6:14 pm

No updates just yet, apart from some bastards breaking both mirrors off my car when it was parked in the street :evil:

I'm nearly finished setting up the workshop at our new place, so I should be back to working on the car in a few days

Beelzeboss · Postby **Beelzeboss** » Thu Dec 06, 2012 7:38 pm

OK I'm finally mostly settled down at the new place. The workshop is semi-organised (enough to keep working on the car, anyway

) and I've made a bit more progress.

Firstly my new tyres arrived. They're Federal 595 Super Steels in 205-60-R13.

I've also stripped the auxilliaries off the engine in preparation for removing it once more to fit the dry sump system. I bought an engine stand at the recent hare and forbes sale to make it easier to build the new sump and supercharger manifold.

I've made a bit of progress on the dry sump pump.

The jig for machining the bores for the gears:

This ensures they're all the same. I've only machined one of the bores but to do so I had to make a new boring bar.

It's pretty rough but it did the job. The pocket for the gear is bored to 38.12mm for a 38.10mm diameter gear and 30.50mm depth for the 30.48mm width of the gear. This should leave enough running clearance so nothing hits. The aluminium will expand more than the steel gears so the clearances should increase and it shouldn't seize (well, that's the theory. I might have not given it enough clearance, we'll see once I've got it assembled)

I'm on uni break at the moment and I've put pretty much everything aside until the MX-5 is done, hopefully I'll make good progress.

Things I can think of which are left to do on the car:
Dry sump (inc. pump, pulleys, sump, lines, tank, cooler)
Supercharger (inc. manifold, fuel rails, fuel lines, pulley)
New exhaust (I can't find room for the drivers side exhaust with the dry sump stuff, I'm thinking sidepipes which join back together to exit at the rear to be legal)
Replace rear main seal
Install Walbro 155 lph HP pump
Install 1.8L rear end
Modify bonnet for supercharger clearance
Reroute coolant hardlines (again)

Simple, really :roll:

...

Hjt · Postby **Hjt** » Thu Dec 06, 2012 7:40 pm

mate are you still local?

Beelzeboss · Postby **Beelzeboss** » Thu Dec 06, 2012 7:41 pm

Yeah, only moved to West Pymble.

Beelzeboss · Postby **Beelzeboss** » Sat Dec 08, 2012 2:13 pm

Found time to bore another of the gear housings. The gears mesh pretty well, I'm happy with how it's going.

I've got the process down now so it shouldn't take long to finish off the other housings.

Beelzeboss · Postby **Beelzeboss** » Mon Dec 10, 2012 11:21 pm

I'd say the pump is around 70% done now, not including the mounts or pulley. I've bored out all the gear pockets and most of the bearing ones.

The bottom right piece shown in the last pic slipped in the jig after the last cut. The hole is the right diameter and depth but now has a huge burr at the bottom. I might be able to fix it, I'll try tomorrow.

To finish the pump I have to drill and tap the inlets and outlets, bore out the end piece for it's second bearing and oil seal, put a keyway in two of the gears and make the drive shafts, pulley and mounting bracket.

bruce · Postby **bruce** » Tue Dec 11, 2012 3:24 pm

Did I miss something - did you get it engineered/registered?
Didn't know a supercharger was going on.

Beelzeboss · Postby **Beelzeboss** » Tue Dec 11, 2012 6:54 pm

bruce wrote:Did I miss something - did you get it engineered/registered?
Didn't know a supercharger was going on.

Havn't done any of that yet. The car was finished but leaking oil from somewhere and fuel from one of the injectors. Since I have to take the engine out and probably replace the sump I figured I might as well convert it to dry sump. Also rather than having the injectors cleaned I'm installing some 340cc ones I have. This needs a new manifold and fuel rail, so I thought I might as well put on the supercharger

Also I didn't want to do ALL this work for 150whp, I prefer the sound of 250whp (with any luck).

Beelzeboss · Postby **Beelzeboss** » Wed Dec 12, 2012 8:41 pm

I want to take the engine out tomorrow so I took the opportunity to measure how much clearance I have for the supercharger. It looks like it should fit and still be legal (able to see the ground 11m ahead of the driver) though I might have to locate the injectors inside the manifold. Not sure if that's possible but I don't see why not, the only downside I can think of is if there's a fuel leak overnight it could hydrolock the cylinders, since it would be leaking inside the manifold.

And a shot showing how big the power bulge will have to be in the bonnet.

Muzdaman · Postby **Muzdaman** » Wed Dec 12, 2012 8:43 pm

I like where this is going.

Beelzeboss · Postby **Beelzeboss** » Wed Jan 09, 2013 5:01 pm

Muzdaman wrote:I like where this is going.

Progress has been delayed because my 323 daily driver was backed into just before christmas. I bought a replacement which needed a bit of work (you didn't think I'd buy a perfectly functioning car, did you? :oops:

) so I've been concentrating on getting that on the road. The only thing it needs is new I/C pipes which don't run through the battery tray and a small rust repair on the passenger side rear sill.

The offending battery tray hole

The new intake pipes I made (both turbo to MAF and MAF to filter) are 316 stainless. The original was mild steel and didn't look great inside, and with the new pipes I'll be able to box the air filter for added legality.

Hotside I/C piping is going well

I'm also replacing the intercooler with a better made and better flowing unit. I had this from when I was turbocharging the MX-5. I can't decide whether to convert it to dual pass or run a pipe all the way around the cooler. I'll not be chasing any more power than stock so the intercooler should still flow plenty as a dual pass. It will simplify the piping immensely.

Rust repair. I didn't know about the second hole when I bought the car

Still, this will all be hidden beneath the sideskirts to I won't need to get a perfect colour match. I'll weld in a replacement panel, put on a thin skim of filler and leave it in primer. It's not a show car, haha.

Lastly the exhaust is a bit weird. It has a split 3" dump and 3" cat which then transitions into what looks like the stock nissan 2" system.

I want to make a 2.5" rear section or maybe even 3" but I'm not sure I can be bothered.