Trav’s Race Build: from B6 to Big Bore BP-Z3

[Scoota]

Ah, what the hell... Check this out!!!!!







I can’t wait to hear these things roar!!!!

I need to send a huge thanks to Russ. I owe you one!!!


Sent from my iPhone using Tapatalk

[Scoota]

Hi Folks.

Sorry, I’ve been too bloody busy to post much in the last week or so. Here’s an update...

• The wiring is done and the ECU is in.
• The engine is almost finished. I expect to pick it up at midday tomorrow.

So, I’m about to start the sprint to the finish. Can you believe it, I’m still ordering parts over the internet and sorting out orders and issues over the phone. I’ve had some pretty serious dramas over the last week, but most of them are now resolved. Sadly, my camshafts are still not in the country. Competition Systems are still not my favourite vendor, but more on that another day.

Some small victories...

1. The head work is all done, save for the big cams. The over-sized valves went in, and so did the springs that suit the big cams. Thankfully, there is plenty of room in there for the big cams - no need for reliefs under the lobes.

2. Ange has checked the clearance between the valves and piston, and we are not at risk of bending valves, even if the VVT goes haywire and sends the inlet cam to “full advance”. Phew!! That’s a relief (pun intended). The small amount of extra lift on the big cams will be accommodated without an issue.

3. I’ve got a PiperCross C6004 filter on the way, arriving tomorrow hopefully. It’s 115mm tall, and it covers all four trumpets. It looks like the extra space that I’ve made around the master cylinder will be required. Fingers crossed!!

4. The BTI Digital Dash from “Tuned By Shawn” fits nicely into the dash binnacle. Sadly, my dash binnacle is very old and brittle and it smashed to bits during the fabrication process. It’s holding together, good for Dyno day, but I’ve more work ahead of me here.

5. The engine is due tomorrow.

6. I’ve got pretty much all of the hoses and fittings required for all of the plumbing:
- Oil pressure,
- Fuel pressure,
- Coolant pressure,
- Oil cooler,
- ITB vacuum,
- Brake booster,
- Catch can,
This took bloody ages to work through, and involved a spreadsheet. Honestly, about 8 hours, and lots of head scratching. I probably should have drawn pictures too. Let’s hope I got it all right. I’ll know this weekend!!

7. The engine is due tomorrow.

Okay, some pics...

Ange’s “engine room”:


Ange has plugged some of the unused coolant fittings for me. Very neat!


I’ve been test-fitting the ITB’s and Manifold.


The water pump pulley got a 10 second run and a quick squirt...


The length of the FlowForce injectors freaked me out, but Nigel put my fears to rest. They provide a washer to space the fuel rail up a tiny bit so that they fit. Phew!!


The loom needs to be “split tube” conduit covered, but getting the ECU mounted made me so happy. Ignore the brass screws - they’re not the final solution. Good For Dyno Day (GFDD). That’s my current approach to completion of critical path activities.


I bought some tools from eBay...


More eBay goodies...


Here’s the display, mounted.


The dash suffered terribly...


I’m happy to report that the new seat mounts, roll cage, harness and my new helmet all play well together. It’s a struggle to get in and out though!!!


I’m going to install a quick release steering wheel boss as a trial. It adds 60mm of length to the steering column, which I’m not a huge fan of, but it will make it easier to escape a fiery crash, heaven forbid. No pics, sorry. It’s an NRG unit, I think.

Phew! Time for bed. More updates soon!!!

FYI... I get my engine tomorrow!!!
7 days to Dyno Day!!!!!!!!!


Sent from my iPhone using Tapatalk

[Scoota]

Note: the head shown with the trumpets and ITB’s above is my spare head, not the “race engine” head.

Zzzzz....


Sent from my iPhone using Tapatalk

[Scoota]

One last thing... Ground hygiene. A huge amount of time went into making sure that my grounding hygiene is spot-on.

I had to pull the bulbs from the tiny indicators on the side of the guards in order to separate the “front harness” from the body. I was working on achieving “Star Point Earthing” by establishing a “main engine earth”, separated from other connections to the body. Those indicators are on the front harness and are grounded to the body. That part of the loom is hiding. This took me HOURS to find. So much head scratching. I traced every visible millimeter of the loom and I couldn’t find a connection to the body. HOURS!!!

Please, I hope someone benefits from my experience. If you need a more detailed explanation, shoot me a PM.




Sent from my iPhone using Tapatalk

[Scoota]

Also, I have a new CAMS logbook. It includes all of the cage details, lists my engine capacity as 1930cc, and lists my bore and stroke as 85mm for both. Happy days!!


Sent from my iPhone using Tapatalk

[Scoota]

Also, lots of helpers will be arriving on Saturday to help with the installation and the plumbing and whatnot. I hope I’ve got beer.


Sent from my iPhone using Tapatalk

[Scoota]

I thought this day may never come...



The most valuable thing I have ever had in my trailer. Ange, that is. The engine is worth a bit, but Ange is priceless!!



Sent from my iPhone using Tapatalk

[Scoota]

It was an anxious drive, but the eagle has landed!!






Sent from my iPhone using Tapatalk

[bruce]

I think engines look their best when not in the engine bay.

[ManiacLachy]

Yep, that's too beautiful to run. Stick it in the living room on a pedestal!

[GR124]

yep, too pretty to be in the car. Thanks for sharing your build, this forum needs builds like yours.

[RS2000]

Very nice!!

[KevGoat]

yep, too pretty to be in the car. Thanks for sharing your build, this forum needs builds like yours.

completely agree.



Sent from my SM-G930F using Tapatalk

[The American]

I’m enjoying this.

[Daffy]

I’m enjoying this.

Ditto. Both Ange and you are doing a great job