Build thread

[speedjunkie]

Last night Bodgan brought over the new board he made for cruise control. We had a couple drawbacks though. The car is up in the air and since my speedo reads off GPS I didn't know how fast the rear hubs were spinning to set the cruise control, and as it turns out I think the cruise control shuts off immediately when it senses no load on the wheels. I put it in gear in fourth gear around 3k RPM if I remember right, and as soon as I set the cruise control and let off the gas pedal it revved about 1k RPM higher for a moment and then dropped to idle. We tried the old board and it did the same thing.

I should be getting the replacement caliper and bearings on Friday, so I'm excited about that haha. Tonight I went to ACE Hardware for pieces to build an installation tool to install the bearing. It came out OK. It's not perfect but I think it'll work.

[speedjunkie]

I got the caliper today. I disassembled it and it's in great shape. Now for the bearings tomorrow night, then reassembly. WOOHOO!!

[Shadowden]

Is everything else good to go for Sunday?

[speedjunkie]

Now that I'm late to respond to this...lol.

I rebuilt the brakes yesterday, pretty much without a hitch. When I pressed in the new bearings they went in really easy, but I got them just a tad off and one side of the window is about 1mm into the opening on the caliper. No biggie though, they still work well. When I first bled the brakes and I tried setting the e-brake it was still very loose and I had to crank it back all the way and it still didn't hold. Then I realized I hadn't pressed on the brake pedal yet. Once I did that the e-brake worked fine. However, on the test drive I noticed the brakes were still spongy. I'd have to press on them twice to actually brake. I picked up my buddy Berto and we went to the 719 meet and I met another FD guy there that just moved here a few months ago. After we drove around a bit more I got home around midnight and jacked the car back up to bleed the brakes again.

I was planning on going for a drive with Andy today but I didn't get finished with the car until about 230am and didn't get to bed until 330 so I slept in and missed the drive. Then I saw on facebook that there was an FD at the U Pull and Pay in Aurora so Bobby and I went up there to start taking what we needed, and that turned into stripping off anything that was good haha. Then Sean Gunn got up there around 230 and we started stripping EVERYTHING off the car whether it was good or not haha. We ended up leaving with nothing because we had about six wheelbarrows full of parts and I thought we would be paying over $1000, so we're supposed to go back tomorrow and either get the whole car or get just the parts, whichever is cheaper since their site lists good prices on parts alone. We didn't finish until about 5 when they closed, and we're still not really finished.

Tomorrow morning I'm going to PCS Motorsports so he can sort out the tune some more.

[speedjunkie]

I went to PCS this morning and we went for a drive where I could not get the car to replicate the problem haha. So basically we got nothing done this morning. I told Travis I'd send him the logs showing the issue, although Chris told me he couldn't see where the problem was all the times before. But I did see where Travis was making corrections to the map so Andy and I went for a drive tonight and he smoothed out all the lean spots, or at least the major ones I always ran into on the highway. He said he wants to fine tune more but I figure maybe we'll do that this weekend or something. Either way I'm super happy with how it is already.

[speedjunkie]

Last night I made some new mounts for the rear of the radiator, only because I found a bracket used in home building while I was at ACE Hardware that would be perfect haha. The only problem is they might be a little too thin. Anyway, I chopped it in half and modified them to work. I might paint them at some point but the one on the driver's side was kind of a PITA to put on, so they'll probably stay this way for a while lol.



About Sunday or Monday I started pulling the IC out to see about modifying the IC piping to use a Vband clamp between the elbow and piping and then use either Wiggins clamps or LPS clamps at the IC on both sides. The piping will need to be massaged a bit though to work, especially since I'll be raising the rear of the IC a bit to increase airflow to it.

Today I started making the sides for the IC part of the ducting. Here are the two sides for the IC, waiting for them to cure. They don't look like much just yet haha.


I might be cutting the radiator piece to drop down the middle of it to give more air to the IC. At the rear of that piece it's about 1/4" above the condenser and I was thinking about cutting the back and dropping it down until it's just about sitting on the condenser which would make a trough directed right at the IC. My only concern is if it will push the air for the condenser to the sides since air follows the path of least resistance and the sides will still have more space. I might just leave the radiator part the way it is and block off the back part of it so air doesn't slip past but is caught and pushed up through instead. This is what I mean.

[speedjunkie]

After some more research I discovered why my horns aren't working, X09 is disconnected. I thought what I was looking at went to the crash sensors but those have 3 pins in the blue connector and X09 has 4. So now I'm wondering if I disconnected it for some reason and didn't need to.

[speedjunkie]

Horns are working again, WOOHOO!!! I found the connector for those two X09 to plug into and all is good again. Now I just need to fix the water injection, which I'll work on while I have everything torn apart. I'm hoping to take the car out again this weekend though so I need to hurry. I'm also going to pull out the wire I ran from the steering column directly to the two horns while I'm at it.


I'm still waiting on the fiberglass to cure. I put a lot of hardener in and applied it to the fiberglass sheets around 230 today, it's ridiculous. I also had another thought about getting air to the rear 2" of the IC. Instead of making the cut I was talking about earlier and dropping the whole panel down, maybe I'll just cut a hole in the back of the radiator ducting the length of the IC and then duct that up. The air might be warmer since it's going over the radiator or condenser first, but I'm thinking if I'm moving at speed it shouldn't be that bad and maybe any air would be better than none.

[speedjunkie]

I spent the day today troubleshooting the water injection issue. I did continuity tests on all the wires, and in doing so I discovered I had the TPS wire connected to the RPM terminal at the ECU. So it's fixed, right? No, still doesn't work. I checked for power where it should be and everything was good. I checked to make sure the harness for the pressure sensor was good. So basically the control box is getting power and all the info it's supposed to get, but it's not doing anything. And of course FJO was bought out by Holley right after I bought the kit and the only part you can't get anymore is the part I need because Holley uses their ECUs to control the system. I'm going to email FJO and Holley to see if I can get a new one by any chance. I'm also talking to people to see if someone has a spare. If I don't have any luck I'm going to talk to Snow Performance in Woodland Park and see if they have anything similar that uses an injector.

I also changed out the connecting rods on the headlights so the passenger light doesn't flop anymore.

[speedjunkie]

I went to Snow Performance today and they told me they are releasing a new kit called Stage 4 in January and it uses a fuel table like mine. He said it will be about $500 but they give a $50-100 discount to locals along with 10% for military and I think he said another 10% for some other reason I don't remember. So that's not too bad. It's a plus that if I ever have problems or need anything they're right here.

I guess I'll be getting a new bumper this winter. I pulled too far into a parking spot tonight at Sean's shop and crunched the bumper against a parking block. So I'll be replacing that and the sideskirts and maybe the diffuser also.

Berto came over today and removed his bumpers and sideskirts from his AE86 so he could sell it to a guy from Denver. Before the guy got here Berto let me drive the car. It was awesome but his clutch engaged hard and fast, so I've decided I'm going to order the sprung clutch discs for mine haha.

[chickenwafer]

I went to Snow Performance today and they told me they are releasing a new kit called Stage 4 in January and it uses a fuel table like mine. He said it will be about $500 but they give a $50-100 discount to locals along with 10% for military and I think he said another 10% for some other reason I don't remember. So that's not too bad. It's a plus that if I ever have problems or need anything they're right here.

I guess I'll be getting a new bumper this winter. I pulled too far into a parking spot tonight at Sean's shop and crunched the bumper against a parking block. So I'll be replacing that and the sideskirts and maybe the diffuser also.

Berto came over today and removed his bumpers and sideskirts from his AE86 so he could sell it to a guy from Denver. Before the guy got here Berto let me drive the car. It was awesome but his clutch engaged hard and fast, so I've decided I'm going to order the sprung clutch discs for mine haha.

Snow is local to the Springs?? Didn't know that, awesome!

Hey...you should see if you can get me in on the Stage 4 W/M kit deal, I need one! LOL

[speedjunkie]

Well they're up in Woodland Park. I've known for several years that they're local but they didn't have anything I was interested in until recently. I'll ask them if they consider Greeley local as well lol, or what they consider local. I'll let you know.

[chickenwafer]

Just buy two and I'll give you the $ for mine LOL

[speedjunkie]

I love the system so much I wanna put two on my car. Lol

[chickenwafer]

One pre turbo one post turbo!