Andrew's '93 NA6 - KL V6 swap

[Guran]

Not sure if anyone is still reading this but I'll keep posting so there's a record of what I've done.

Always excited to see a new post in this thread, particularly when it says the last post was made by yourself. Normally means new content

Oh we're still reading your thread with GREAT interest. Don't worry about that. Please keep it coming!

[bruce]

I'm always reading...

[Beelzeboss]

Well that's good to know

It gets a bit boring posting with no feedback, feel free to post whatever's on your mind. I'm expecting more posts like: "why are you making your own throttle body you idiot, just get the damn thing on the road again it's been nearly 2 years FFS!"

[sailaholic]

Yup I'm still reading too....hurry up and get it finished, the last bits take the longist, well normally, you might be the exception.

[Black_Penguin]

Definitely in the 10% of the project that takes 90% of the time.

[Okibi]

Subscribed.

[16bit]

what about OEM mustang throttle bodies?

not cheap but looks legit.

http://www.americanmuscle.com/accufab-t ... -70mm.html

[Beelzeboss]

Cheers everyone, I'm definitely on the home stretch now. Probably only 12 months left

That throttle body looks great 16bit, but it's $270! Being on a student budget means my OEM options would look more like this mustang throttle body:



Also I've had a bit of a think and I reckon I can make a better throttle body than the one I posted before. I'm going to try to make a dual bore one with the same pattern as the supercharger, so it will bolt directly to it. Two 52mm throttles will give me slightly more area than a single 70mm and having them closer to the supercharger means more immediate throttle response... it will also look way cooler which is important
I'm going to make it out of the piece I cut out of the centre of the adapter plate.

[16bit]

the economics of being able to do something yourself.

in most peoples circumstances the custom fabricated option would be more expensive than off the shelf!

power to you.

[Brainflex]

Another reader here. I look forward to your posts and your progress updates. Keep them coming. I have a great deal of respect for someone who can build n modify as you are doing. Better than check book engineering.

[Beelzeboss]

the economics of being able to do something yourself.

in most peoples circumstances the custom fabricated option would be more expensive than off the shelf!

power to you.

That's true I just don't put a value on my time. If I did it would almost certainly cheaper to buy off the shelf parts hehe.

Another reader here. I look forward to your posts and your progress updates. Keep them coming. I have a great deal of respect for someone who can build n modify as you are doing. Better than check book engineering.

Thanks Brainflex

On Thursday at TAFE I knocked up an intake pipe for the new throttle body (not made yet). I'm pretty pleased with how it looks, though it's a little bit close to the firewall and the transition from square to round could be better.









Let me know what you think

I've got exams in a week and a half but in between studying I'm hoping to get the throttle body made.

[lightyear]

Good to see your still going. Alloy is nice to work with, that looks like it should do the job by the time your finished with it.

[Beelzeboss]

Good to see your still going. Alloy is nice to work with, that looks like it should do the job by the time your finished with it.

Thanks lightyear, I love working with alloy. It's so great to machine and weld.

I've made the two 56mm blades for the throttle body. This gives slightly more area than a single 75mm but since there are two shafts in the way it works out about the same.



I also now have the material for the fuel rails. 16mm tube and round stock and some 22mm which I bought from the scrapyard ages ago, all stainless.



Finally, I've nearly finished flattening the base of the intake manifold on the shaper. There isn't very good lighting in this corner of the workshop, hence the bad pic. I took a video but it's almost unwatchable.



On Wednesday the 26th after my last exam I've got 6 or 7 mates coming over to help take the engine out and maybe change the head gaskets. Until then I doubt there'll be much progress (unless I need some further procrastination from study )

[Beelzeboss]

I had a bit of spare time today to finish flattening the base of the supercharger manifold. It now sits perfectly flat on the engine with no rocking



I took a video of the shaper working. For those who haven't seen one of these before you can pick them up quite cheap and they're great for flattening surfaces, making internal and external keyways and splines, cutting dovetails and a heap of other operations. Not a substitute for a milling machine but much cheaper, and a milling machine will have trouble with internal keyways and splines.

[Beelzeboss]

OK I've changed my mind again The car is being reassembled N/A and rego'd, I'll finish the supercharger bits while driving it around and fit them later. I wrote out a complete list of everything that needed to be finished before I could supercharge it and it was more than I initially thought. 95% of the work can be done without access to the engine so I figured I'd just put it back together N/A and enjoy it while I fabricate the charger parts.

First step was to locate the leak at the front of the sump. I put talcum powder on the sump and watched, this is what it looked like 1/2 an hour later.



The leak is just coming from the bolt! No need for more welding.
I did the same test for the leak at the back and it turns out it was just at the sump-engine block junction so that means the sump doesn't need to be welded at all!

Next up was to take the heads off



And then fit the ARP head studs



Porcupine motor with 1 head gasket fitted





The heads were then lapped flat on a piece of 16mm thick plate glass which is extremely flat. They were found to be slightly warped but cleaned up nicely. Unfortunately I didn't take any pics of this process, but just imagine the head doing a figure 8 motion on some glass which has wet and dry glued to it.



I also painted the rocker covers black. It was a rush job but looks better than the chipped red. At some point I'll have to get them sandblasted and paint them properly, it was impossible to get the sandpaper into some of the areas of the covers.



A couple of mates are coming round soon to finish reassembling the engine and hopefully get it installed back in the car. That might have to wait until tomorrow because we're also going to swap in the 1.8 diff and rear brakes that I bought ages ago.

Once that's done I just need a new TPS and to cut a tiny amount of the intake manifold to clear the bonnet.