Sr20 Conversion To Ke55 Plus Rebuild Plus Pimpage

[JDM55]

so made the call today and i have an appointment with an engineer ,

whos going to come out and check over my car with everything that ive done so far,

I'm deffinatley nurvous about the visit, my past dealings have been less then pleasant ,

so has given me a sense that there all mother $^%%&$^#&$*%(#$(#*&$$&$&$*#*#*

how ever its any ones guess at this stage on what hes going to say , all i know is the work that ive done

has been to the best to my ability and heres hoping he dosent pick to much stuff,

 

then theres the future mods like coil overs and larger brakes that i want to do,and a few other things to talk

about, so yeah kinda a big deal for me , ive come this far ,just gone into my 3rd year of the build, and things are getting

closer , so last thing i need is an "engineer"( who seem to all have there own different rules any way)telling me ive done things wrong.

 

on the flip side of that trying to stay positive and fingers crossed the guy isnt one of those.....

 

so the 20th of this month ,not to far away, just enough time to try squeese a few more little jobs in....

[JDM55]

haha so i just noticed this thread is getting rather long , up to 30 pages with 435 replies and 29373 views!!! crazy ,

 

any way , ive been doing stuff this weekend,trying to get some more things done before Mr engineer comes for a look.

 

so this week end this was a small job i had to do was make up a clutch line and connect the master down to the slave,

found one of my old brake lines and chopped it up so i could use one fitting that would definatley fit and work,

( I'm so paranoid now about these types of fittings after the hole 3 attemps at doing the brake lines my self ,plus the

nasty job of the guy at the brake shop ,he flares my lines and nearly all of the fittings leaked.

any way i bent up a small line heading down to the slave ,i took this line to the brake line man, against my better judgement,

he put a double flair on the line for me, it cost nothing fortunatley ,how ever .....

then i found an old brake line bracket,

then from there i found a old brake hose that had what i thought was the right connection on it,

 

hooked it all together and filled the master up, and proceded to bleed the line with my very trusty assistant,that also got some

paint on it LOL colour matched .....

 

my trusty bleeding assistant:::

 

 

pedal started getting firm ,continued to bleed then suddenly the pedal went soft again......

turns out , big leak, again!!! was not happy,the leak was coming from the connection that the brake man had done,

DOH!!! I knew i should have trusted my judgment on that one, grrrrr well leasson learnt ,twice burnt.

 

being the experimenting kind , i pulled the line out still connected to the rubber hose that was still connected to the slave.

found that the leak was coming from around the threads of the rubber hose end,i tightened this right up as far as it would go,

it was just about to break from the amount of pressure i put on the dam thing, blew the air gun around the threads to see if there was still

fluid getting through...........

 

there was..... some how i came up with the mad idea of welding the hard line connection to the rubber hose end,lol wrong move, but it was worth a shot.

i welded careful around the threaded part and it was actualy working !!! nearly got right around the hose end ,but it must have gotten way to hot,

because the hose just poped straight off the hose end! aaaahhhhhhhhhhhhhhhhhhhh god dam it ,

 

still not giving up!!! after all this stuffing around ,i had to get this working !!! was on the mission from nam hahahha

 

 

put the welded hard line in the vice and ruffly guessed where the end of the hard line was inside the connection,

idea this time was to cut the welded connection off and try to save the hard line,becasue 1 the top part of the hard line connection was good and didnt leak, and 2 i didnt want to have to make up a whole new line ,that takes ages, sooooooooo SAVE THE HARD LINE!!!!

 

cut thru the welded connection ,and managed to slice right at the end of the double flare :) so pulled the line out and didnt lose much lenght of the line ,

 

nextt!!!!!!!! took the hard line this time to a brake service center, NOT MR BRAKE MAN !!! they did a nice job of the double flare ,was fairly round ,

this cost me 11 $$ i thought that was a bit much for a small job like that ,it took the guy like 1 minute and it was done , any way i could handle

paying 11 dollars for one flare if the dam thing actualy did not leak! also i got a new clutch line custom made to lenght and with the proper end connections on it.

 

 

 

 

 

back to the car, fitted the new hose to the slave , fitted the braket to the new hose, then fitted the hard line to the hose,

be fore i go on ,any one with a sr20 in a corolla will know, its DAM TIGHT DOWN THERE ,JUST LIKE A ....... lol

but under the car again ..... its like my second home these days ,may as well put a matress down and sleep under it and wake up and keep working haha.

 

any way hooked up the lines to where they were spose to be

, made every thing dam dam tight, i was sweating from the amount of pressure i put on the connections hahha,

filled up the master the second time, and started the bleed process all over again ,

this time leak!!!!!!!!!!!!!!!!!!!!!!! f#@*$^@&*&@*$^*^*(!*(#*!(#&($&*$(@&(*#$@&mother $*&@#*$&@*#&*@#$stupid@*$@$*&$*@

 

couldnt believe it ,are you F#$%ing serious!!!

any way this time the leak was from the master to hard line connection!!! well at least the double flair and new custom hose fully worked .

after a long bout of throught spanners at walls and screaming alot of nasty words,

i decided to try one more time and just try to tighten the connection a bit more....

 

now doing this may sound like the obvious thing to do, but if you knew how much pressure i put into tightening them the first time

you would probably advise against it, any way wiped away the leaky fluid and got the flare nut spanner down there and tryed to tighten it again.....

 

 

just a note ,to tighten the master connection you get about a 1/4 if not less of a turn then you have to take the spanner and jam your hand up under the engine,(which isnt at all enjoyable ,then get the spanner back on the flare nut,) and out of doing that you get like half a 1/4 of a turn ,plus you have to put fair amount of pressure to even move the spanner!! so long story short ,that connection is not easy to get to,

bla bla bla raa raaa raaa i managed to tigthen the connection about 1/4 of a turn more .

 

 

so again 3rd time lucky???

bleed the clutch line for a while and pedal got very firm and springy, by the last depress of the pedal i had to use my foot and hands to get the pedal to the floor!!

shes bloody firm thats for sure .

went over the lines very carefully and cleaned and wiped them so i could see if there were any leaks.................................................

[JDM55]

some how it held, no leaks !@! well so far its not leaking and the pedal is very firm, i even set my phone up and videoed the slave moving in and out,

so as far as i can tell its working ,but ill check it over the next few days and see how it goes...

 

 

 

another thing ive been doing is wiring, now i don't mind wiring, some people absolutely hate it,

i find it interesting and great when you finish and it all works like magic,

how ever this kind of wiring is insane!!!

 

i had to chop my engine loom completely in half!! and record every wire and then ,fit plugs to them , and then connect one half to the engine and then the rest inside the car, just doing that, took a very long time , at least 2 days of work and then a lot of fiddley stuff in the car,

fitting the computer and fitting a relay board all ready set up , and many many wires!!!!

even fitted the ignitor chip and boost solinoid under the dash,, hopefully mr engineer wont make me move it cause it looks like ass ,lol

 

but wiring this amount of wires ,takes a lot of time,its a very slow process,

what i do is right down exactly colours of wires and how a plug is set up, where the wires are going and what they are used for,

then i can refer back to what ive done .

 

 

 

got alot going on in there !!!

[BUZ440]

back to the car, fitted the new hose to the slave , fitted the braket to the new hose, then fitted the hard line to the hose,

be fore i go on ,any one with a sr20 in a corolla will know, its DAM TIGHT DOWN THERE ,JUST LIKE A ....... lol

but under the car again ..... its like my second home these days ,may as well put a matress down and sleep under it and wake up and keep working haha.

 

 

Bahaha

[_FNQ_rolla_]

It’s been a little while since I have dropped in and had a look at your thread and it is looking mighty fine.

 

Hey with your high quality standards you will have nothing to worry about when the engineer is looking over the car.

 

Wishing you all the best for the 20th.

[chestikoph1]

Hey Ryan, if you need any nissan wiring diagrams just shoot me message.

[JDM55]

It’s been a little while since I have dropped in and had a look at your thread and it is looking mighty fine.

 

Hey with your high quality standards you will have nothing to worry about when the engineer is looking over the car.

 

Wishing you all the best for the 20th.

 

 

 

cheers for the comments there mate :) fingers crosssed !!! just hoping its up to the standard of what he usualy looks at,

i know this guy has engineered alot of modified cars , so yeah hes probably used to seeing top notch work,

just hope the fact that ive done just about every thing myself dosent reflect poorly against me, with other people being

loaded with cash and being able to send there car to mechanics ,engine shops brake shops etc etc , but we will see soon!

[JDM55]

Hey Ryan, if you need any nissan wiring diagrams just shoot me message.

 

 

haha cheers man , i think i pretty much know what I'm doing sort of lol,

well i managed to get the engine running twice now ,once in the car and once sitting on a pallet,

using the basic set up, but its a bit tricky fitting it in the car and joining the billion wires ,

at the moment I'm just trying to get the basic computer,fuel pump ignition etc working , well

I'm going to do a test start ,same as the first time i got it going, tho this time I'm making things a

bit more permanant , realy i just have to figure out the boost solinoid and vacumm lines and charcoal canaster,

stuff like that , again not sure how to set that stuff up with the engineer coming ,maybe ill ask him about it,

,hope he lets me keep all that stuff hidden away just looks untidy ,theres enough chaos going on in the engine bay as it is lol

cheers tho

Edited January 10, 2012 by JDM55

[JDM55]

so back to it this weekend,few small things to do this weekend,

i was going thru my boxes ,and came across a overflow bottle ,totaly forgot that i had it,

so thought id try fitt it in the engine bay,

 

 

 

 

 

 

had to make a funky bracket, so got some card board,and came up with a shape,cut it out from a couple mm steel plate,drilled the holes,and weld some small

nuts to the back,for the bottle to bolt up to ....

 

 

 

this is the bracket mounted, had a spare mount that i didnt remove luckily,so it bolts straight on there

 

 

 

and then fitted :) looks good and just fits nice and tight,

 

 

[BUZ440]

Those remote oil filters are a pain to service if they sit upright, perhaps look to turn it upside down and use 270 degree fittings?

[oh what a nissan feeling!]

Great work mate, not far off now looks like its coming together nicely. :y:

[JDM55]

Those remote oil filters are a pain to service if they sit upright, perhaps look to turn it upside down and use 270 degree fittings?

 

 

 

yeah i thought about having it upside down, but the hoses were that firm i didnt realy have a great deal of options on where it sat,so

its just staying there, and it was a pain in the ass to get the thing and hoses all together ,i just hope it doesnt leak,

how ever i have access to all the cleaning gear i could want so a bit of oil from the filter change wont be a big deal to clean,

I'm more worryed about the sandwhich plate and hose connections , spose we will see soon

Edited January 14, 2012 by JDM55

[JDM55]

Great work mate, not far off now looks like its coming together nicely. :y:

 

 

thanks man, yeah its sloooowwwly falling into place, just a little bit at a time and then all of a sudden

its getting closer and closer, having a big clean session tomorrow if i can get under the thing,

i realy messed up my knee so I'm not moving to well at the moment, still managed to hobble around today and get a

bit more wiring done ,soo many wires in this thing .

got the engineer coming on friday ,will be interesting and abit nurvy to what hes going to say ,either way

its getting closer and my next plan is to figure out the radiator and fan set up,get some water running through the engine,and hopely

do a start up very soon ,just need the cash for a radiator!

[JDM55]

well didnt get to much done this weekend , just manged a few small things as some how i stuft my knee realy bad ,

and its the cars fault ,lol ,was in a bit of an awkward position and was trying to pull the car forward,

would think it would be easy, but my cars very heavy now and i strained abit to move it , heard a clicking sound

thought it was the tyre running over something, but as it turns out, it was the ligaments and tendens in my knee that were tearing

,not good so I'm hobbling around on one leg now!! just hasnt been very smooth the last year, after the whole hospital episodes

and being not even well enough to go to work let alone work on my own car, seems I'm just not having any luck.

any way I'm down to one leg and hopefuly that wont fail me as then I'm f*^&Ked ,and back to the side lines :(

and the engineer is coming this friday!! , only 4 days to go and i can't do any more to the car before he comes ,

so hopefully its in a half decent state to look at, mite try give it a clean over just before he comes ,make it all

shiney ,lol ,not that that wil help him make up his mind on what ive done is good or not ,but yeah anythings worth a go ,

don't want this to go like the last time i had a guy come out, jesus ill take the guys head off with a slide hammer hahaha

just joking , but realy have no idea what to expect,.......

[JDM55]

engineer is coming tomorrow,so been under the car cleaning all the dust and crap off the parts,

 

 

love the custom grill

 

 

and what the engineer will see....