Sr20 Conversion To Ke55 Plus Rebuild Plus Pimpage

[JDM55]

Hats off to you mate, a ʞ©$ɟin top effort. I'll definately be reading back through your thread for info when i get back onto my car.

Well done dude

 

 

 

thanks there mate, i hope theres something useful in amongst all the babbling haha,ive tryed to supply info that ive personaly confirmed that works,

any questions you can all ways email,i don't mind helping out fellow car builders :)

[SLO-030]

Happy Birthday Ryan! Have a good one bloke

 

:party: :party: :party: :party: :party: :party: :party: :party: :party:

[JDM55]

Happy Birthday Ryan! Have a good one bloke

 

:party: :party: :party: :party: :party: :party: :party: :party: :party:

 

 

HAHAH!!!! thanks a bunch i will indeed :)

[kickn5k]

Happy b'day dude!!!

[JDM55]

Happy b'day dude!!!

 

 

cheers man ^_^

[JDM55]

well small update, just been working on the exhaust system , basicly i wanted to do this myself and not pay some one to doing ,

i got some 2.5' stainless steel tube and a hole bunch of bends, 45 degrees, 90 degrees , flanges and gaskets, and some steel rod,

and some exhaust rubbers,

 

some advice : let the pros do this !

I'm managed to complete the hole system in 2 days , but that was working all day and all nite and into the early hours,

and well the result was much less than i hoped for,

if i had some bending tools and maybe a bit more knoledge then probably would have been a much better job,

that being said i didnt do to bad in the way of being my first exhaust , just my welding skills still need improving

 

 

i didnt have acess to the hoist so i done the hole exhaust laying on the ground!

 

 

 

 

first i started at the dump pipe , got a flange to fit , then to work out the shape of the pipe , i drew up a cardboard shape of the floor and designed the shape

keeping in mind clearance from the floor to the pipe, was a bit tricky and very very time consuming!! but worked out a ruff bend ,

then using the card board template of the pipe shape , i cut the pipe to match, then welded it up, since i couldnt use a bender i ended

up with lots of little pieces welded together, this was the only way i could match the floor pan shape , or at least close enuff.

 

the front pipe from the dump pipe looked pretty horrible, the welds were a bit chunky lol stainless wasnt welding together to well,

so i wraped it in exhaust wrap, with made it look alot better, think I'm going to do the rest of it in exhasut wrap as well,

but i ran out so need to buy more, more money again haa

 

 

 

i flanged the front pipe and flanged the cat converter and bolted them together,then put the first set of rubber mounts on ,

for the mounts i used 2 nolathane rubber mounts and some round steel rod,

cut the rod up and bent it in to some hook shapes,

welded the hooks to the bottom of the floor,

and welded some hooks to the cat , and fitted the rubbers to take the weight of the cat and front pipe, tho at this point it was very sturdy and wasnt moving round much.

 

next was the pipe from the cat to the back, yes it looks horrible,just didnt work as well as i planed , mite have to do this one again,

the shape of the floor and how i had it sitting was all up and down and weird ass angles ,was pretty hard to work out ,so it ended up a bit shit.

 

 

 

then i flanged the end of that pipe and flanged a short hotdog muffler , and made some small brackets that bolt to the floor , and onto them i welded the steel hooks,

this was alot more stuffing around ,but avoided welding on to the floor ,later on i found the 3 bolt flange hung down too low for my liking,

so i choped the flange out and welded the hotdog straight to the pipe,

 

 

 

then same again , made a cardboard shape of the floor going over the diff and designed a shape to go over the diff,

again chopped up multipul pieces of pipe and welded them together and flanged them ,

 

that took me to the back end where i fitted a frigen way monsta of a cannon muffler,

this muffler is a varex its got a butterfly in it that opens and closes , theroy being that its spose to quieten down the noise,

and it actualy does work , tho the size of the thing is a bit rediculous , ut I'm getting use to it, for a tip i welded on a dumper, just casue i like that look.

 

 

back on the gound :)

 

[JDM55]

heres a quick vid ,even tho its thru a shity phone mic you can still here how much change the varex makes to the noise level,

but I'm loving the note its got, nice and low with a slight pulse , not what i thought it was going to sound like thought it may have been a bit tinny

with the cannon , but its not

check it

 

http://www.youtube.com/watch?v=lpj84uWQd6U

[rian]

I like that Varex! Is it legal?

[BUZ440]

Nice work considering the lack of hoist,

 

Mine looks the same also following the floor and bends here and there,

[JDM55]

I like that Varex! Is it legal?

 

 

thats a good question ,may have to swap it out for something shit for engineers,either way its staying on the car

[JDM55]

Nice work considering the lack of hoist,

 

Mine looks the same also following the floor and bends here and there,

 

 

haha thanks man , it was bloody hard! was confusing when you have a bend not only bending to the left or right but up and down as well,

done my head in a fair bit , but at least i have some form of an exhaust now , and yeah laying on the ground or should i say rolling under the car then

getting back up and rolling under the car then getting back up etc was a fair efort lol musta done it a few hundred times ,

but yeah finally got it done ,still mite exhaust wrap the pipes ,just so i don't have to look at the multipul random bits of stainless lol

 

but its actualy a big step forward!

now i have fuel , brakes , air intake , exhaust ,all the basic mechanical side done:)

next is a whole lot of wiring ! another mind bender and time consuming exersize, think I'm going to plan out the next bit in detail before i jump into it

so i don't get lost in the world of spagetti

[JDM55]

well ive starrted on some wiring , there is a lot of it to do , i should say a hell of alot ,spent all friday night to 3 in the morning and then all saturday to 4 in the morning , and ive pretty much just made a start on it, theres just so many dam wires!!!! havnt takeen many photos of this , casue its just wire after wire after wire running all over the place!!

 

 

i took the steering wheel off to give me more room to work,so at least ive made a start on it, waiting on a few wiring bits and pieces

so i can carry on , i have a head unit ,an alarm system , a gps tracker ,and gauges and switches an other random things,

so need heaps of wire and solder and tape and all that other electrical stuff ,

but while I'm doing that I'm also fixing up a centre console ,

i was going to make a full custom one , but at this stage i don't want to spend another month stuffing around

realy want to take this thing for a drive!!!!!

so cuting down on alot of things i would have liked to have done , plus money isnt allowing me to do lots of extras,

also i got hold of a smashed up ke70 hand brake console, which I'm going to modd.

 

quick story, went to the wreckers in search of a ke70 hand brake console,

was in luck there was 3 ke70s there !!! how ever all 3 of them had the console broken !! couldnt believe it

any way i found the best of the 3 and found the broken parts and took them with me lol, was going to need to chop it up a bit

any way but first i need to repair it ,

 

centre console :::

 

so idea being with this is i want to use it in its factory position ,to house the head unit and 2 gauges a bunch of switches and the gear stick boot,

but as with the ke70 console, this one was a bit damaged,

the plastic around the mount holes was all broken away so need to fix those bits so it can actualy screw on,

the other small problem is because i changed the postion of the gear stick and modded the tunnel,

i lost the holes for the console brackets , and also the gear stick is in a different position , and the metal shape i made to cover the hole is also different .

 

so even tho this is a stock 55 console it needs to be modded a fair bit, turning it into a custom console lol

 

heres a few things i done so far with it,::

 

this is the stock console i raped from my daily 55 , in prety ruff shape ,with a few broken mounts and

an old stereo frame

 

 

[JDM55]

first thing was to remove the old stereo frame thingo ,

 

 

 

 

for the first modd i need to change the position of the gear stick hole,

i found under the console that the whole centre part could be removed by drilling out

the melted plastic pins and removing a few clips, so went ahead and ripped its gutts out

 

 

 

 

first test fit ,i found the rubber boot and frame were to wide for the console to fit down properly so

they have to be modded ,also the boot was too big for the gap

 

 

[JDM55]

i shaved the sides of the rubber boot and the metal frame that holds it in place ,

 

 

 

since i pulled the guts out of it,it got a bit flimsy so need to make a strenghtening brace,

 

 

 

 

heres one of the broken mount holes

 

 

 

 

want to make a single sheet that covers the entire console front, so started with some cardboard to get an idea of how to go about that,

creased up the card so that it could follow the curve of the console

 

 

 

 

taped it on and this is what i got,sorta like a sk8 ramp

 

 

 

 

back to the brace idea, cut out a small piece of plastic and positioned it and glues it in place,

this made the console all strong again :)

 

 

 

 

next cut out a piece of plastic the ruff shape of the cardboard,

 

 

 

 

after that i sanded both sides ,one side was sanded 500# this make it easyier when i go to paint it,the other side was sanded 180#,

that gives the glue something to grip to ,

 

 

 

 

the next idea was i want to take the plastic piece i cut out and make it conform to the shape of the console, didnt even know if this would work or not ,

but gave it a go any way,

taped down the console so it wouldnt move around while i do the next part and also to give me free hands to work with

 

 

 

with the console taped down and not moving , i taped the plastic piece to the top ,

 

 

 

 

using a heat gun i carefully heated the plastic and using a hard roll of cardboard pressed down on the plastic when it was hot and rolled it like a rolling pin,it soon pressed

the plasic into a ruff shape ,

 

 

 

 

 

 

 

getting the shape closer

 

 

 

as i moved along the shape i taped it hard against the console so when each part cooled off they would stay in the new shape

 

 

 

all heated shaped and taped down

 

 

[JDM55]