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-   -   My never starting build... has started. (http://www.calaisturbo.com.au/showthread.php?t=176455)

TheChad 20-09-09 17:12

My never starting build... has started.
 
pics r up


As most of you in the WA section know over the past six months i have been talking alot about building my 87 calais turbo into something a bit more powerful. The idea is something i toyed with since i first got it, but after driving my mums 07 mazda 6 and feeling that it was significantly faster than my 20 year older turbod beast, i decided it was time to add a little stick.

First the history of the car. it is an original 5sp manual VLCT that is alpine white in colour. the car was made and purchased in SA. when purchased the car was dealer fitted with a full LE spoiler kit, and the paintwor and seats were treated amoung other things. the car cost the original owner just over $35000 all up brand new. the car was owned by an old couple who had a son and a daughter, as the guy got too old to drive it his son said he would buy it, he took the car for a couple of months but didnt make any payments, so the daughters husband offered his father in law cash and the car came to bunbury. i will say the gentleman who i bought it off was a bit dodgey, and there was a couple of slight discrepencies with his story, but at the end of the day it has all numbers matching and was without a doubt still in great condition.

http://i172.photobucket.com/albums/w...3/DSC01281.jpg

http://i172.photobucket.com/albums/w...2noplate-1.jpg

http://i172.photobucket.com/albums/w...6noplate-1.jpg

http://i172.photobucket.com/albums/w...DSC_0258-1.jpg


i begun where we all begin, getting an intercooler. i went for the gktech no holes fiddler, and lets be honest, it is a great entry level cooler, but man that **** was fiddly. whilst i did put on the cooler i did nothing else for the time being. the car did have a hand "guess and hope" spring tipe boost "controller" but it also still retained that thing on the plenum that wont let you go past a certain pressure, so i fiddled and had it as high as it would go. i drove it around like this for a while, and found that the single spinner turbo diff was really letting me down as far as initial acceleration, so i talked about an lsd, but eventualy settled on just buying a whole new rear end disk to disk with a minispool in it (thanks evl51r for that). drove this around for a while too, and then took the car to the drags, i put some crappy csa 15s on the back that had good tread (the calais wheels had little or no tread) and let them down to about 20psi. the car ran a best of 15.5 out of like 5 runs (other 4 were all 15.7-15.9). that being my first trip to the drags in reletively bog standard 21 year old car i was happy.


At this time i also made a few shopping list threads and started looking for parts and recomendations. I got some good advice from some of the more old school WA members (they know who they are, they are always on here). and eventualy settled on looking at a bigger turbo, new injectors and a new computer. so i set out looking, little did i know that this would end up spiraling way out of controll as as i started looking for things i started thinking, ****, i could sure use one of those if i'm doing that. so i started buying a whole load of stuff.

i got very lucky and read a thread by HoldenOn (matt from busso) about his friend (graham)s drag vl that was about to run, just so happened i read the thread just after the motor gave way and graham cracked the ****s, so i smashed out a quick pm and was the first in with the dibbs, one week of very informative pms with HoldenOn and lengthy calls with graham then i was down in busselton handing over a large amount of cash and walking away with:
-garrett 35/40 1.06r ext gate
-6boost himount mani w/ gate
-Specialised Power Porting plenum w/ tb
-Fuel rail w/850cc siemens injectors (probably replace w/ new injectors though)
-Lines to suit all
-turbosmart dual stage boost controller (might not use)
-fuel reg
-3" Dump pipe w/ screamer
-"special" cat converter
-and a bunch of other little things

I was satisfied with the purchase and these things have sat waiting the build for well over 6 months now, stored in plastic in the garage.

i then found a nice head i wanted from over east, that was ported/polished etc with everything you could want done to it, containing a nice big crow tx2. so i bought that and that came with a boot mounted surge tank. I have since realised i may not be needing this head and instead may be buying a whole package motor.

it was then that we had the first majour hiccough. i decided i wanted to move the fuse box as i wanted the room in my bay for a catch can and didnt want the fuses overheating as they would be living right behind the 35/40. we took the fuses thru into the cabin, and found one wire wasnt connected properly, this turned out to only be a heater wire, but alas the car wouldnt start.

http://i172.photobucket.com/albums/w...0092009061.jpg

after an auto elec wasting my time and only managing to dent the car and scratch the front (he got the car to try and start though, ticks over but wont idle). i took the car back not running, with wires sitcking out of the dash. it is quite obvious the previous immobiliser job was a complete hack.

immobilisor wiring:
http://i172.photobucket.com/albums/w...0092009067.jpg

fuses/relays where the sit now till i fix all this then mount them in the glovebox
http://i172.photobucket.com/albums/w...0092009068.jpg

I am still looking for someone to come and fix that or atleast make sure its all in working order. the auto elec is convinced it is the computer, and i am not too fussed becdause with what i am planning an after market ecu is the only option anyway. worse comes to worse ill rip that mess out and start again, hope i dont have to though.

then i got a call from ShaunVL, to tell me his young friend had just written off his r33 gtst so i jumped right in and got a smashing deal on an r33 5sp that had done very little kms and some nice big front 4pot calipers. i have since sent the calipers over to vhr32 over in tas who is currently redoing all seals and widening them to suit some nice big holden rotors, while they are there he is giving them a lick of paint and equiping them with lines and the adaptor brackets to suit my vl.

http://i172.photobucket.com/albums/w...2062009036.jpg

the larger breaks require a minimum 17" wheel to clear them, so i bought these: (17" hdb vx wheels) just need to get some rotors now.

http://i172.photobucket.com/albums/w...0092009065.jpg


i finaly got started on taking the car apart just this week, after so long and constantly putting it off to get new parts i couldnt wait any longer and pushed the old girl into the garage and started taking stuff off. here she sits now as i plan the rest of the build.

http://i172.photobucket.com/albums/w...0092009057.jpg

http://i172.photobucket.com/albums/w...0092009059.jpg

Oliver 20-09-09 17:16

Good work Jack, Look forward to reading/seeing more of this as it comes along. Let me know if you need a hand with anything/parts. :)

leb vlt 20-09-09 17:35

great write up jack, looking forward to seeing the pics..

mike 20-09-09 18:54

really looking forward to seeing this car progress, nice work!

VLWAGONIT 20-09-09 19:06

nice essay boy A+ ;) haha. now finish the story and run some times!!!

TheChad 21-09-09 02:29

pics up

ILLUSIV 21-09-09 09:43

Good luck mate! Cant wait to see the end product :)

EVL 21-09-09 15:41

Nice work Jack, good to see you're getting stuck into it!

TheChad 28-10-09 18:38

Updation! (advice needed!)

motor is almost ready to be taken out. unfortunatly my garage is on a slant so craning it out might be tricky, also not feeling so confident on the beam in the garage, yeah its a pretty good beam, but im still just not sure, just need to disconnect everything from the gearbox, get the airconditioner off, and i think im going to take the turbo/ manifuld off, just coz it will only take about 30 more mins and its also learning.



have been to see lee at sanders racing and heres how my plan goes at the moment. getting the built bottom end delivered straight from vic to lee, when that arrives ill bring all my junk and boltons over to his workshop, followed by the car. lee is going to install/fabricate pretty much everything for me, get an ecu installed and then get the car tuned. in a few months when i get the car back hopefuly i will have the calipers back from vhr32 and ill fit the big breaks then. the breaks will then be joined but a vt/vs master/booster upgrade and everything should be right.




at the moment i am really worried about all the wiring, my engine loom looks to be in 100% perfect health apart from a couple of random wires that shoot off in funny directsion, which means something may be wrong with the fusebox loom, that could be a real hassle if it turns out the problem is somewhere in there. (i am hoping and praying that maybe the ecu copped water damage whilst we had the hole in the firewall open)



i have sourced an alloy radiator that comes with a davies thermo fan, still undecided whether or not i will use the thermo or stick with the clutch.
just in the market for an intercooler atm, i am selling my whole gktech kit this weekend so i will be looking for a new cooler. looking to spend up to $600~ on a cooler (just the cooler, no pipes) wondering what i should be looking for? lee was pretty confident that a gktech, whilst a cheapy, would still be fine to use. and i would be keeping it, but it is easier to sell the kit with the cooler included.


also i was wondering about aircon fans (whilst mine is easily accessible) the old one is chunky and fouls the cooler, just wondering where you can source slimline ones, and do they work just as well?





edit: thanks jack for his help the other day, certainly knows how to sort a bay out.

malpaso 28-10-09 18:53

jdcustom do a cooler kit aswell

EVL 28-10-09 19:05

are you retaining aircon? you will find it very hard to keep cool with big hp, intercooler, a/c condenser and a radiator, especially just using a davies craig fan. I'm on my third round of looking at options at the moment for mine. I've decided again to pull aircon out of this car as it wont be driven during 32+ degree days anyway...

HoldenOn 28-10-09 19:10

Hey Jack, Im glad your progress is now really starting to motor (so to speak lol). Can't wait to keep up to date with the build and then see the final product.

You have alot of parts from Graham's car. It will be good to see them put to good use. If your car has half of the potential and workmanship and time put into it as Graham's did, then your car is going to be an awesome machine.

Now, onto a little bit of info. Regarding your clutch or thermo fan. A clutch fan on a vlt does a fantastic job. Mine is a testament to that. But if you are putting a new radiator in, and you have a 16inch thermo, well just put that on, and see how you go. Graham was going the thermo route.

Lee Sanders has a wealth of info and knowledge. If he says that the Gktech intercooler will do the job with which you are wanting it for, then I would save the hassle and keep it. There are plenty of cheap chinese intercoolers around that people have run 10's with from my reading. Possibly even faster. I would go with a professional's opinion like Lee's as he has been there and done that with alot of things regarding engines etc.

How close is your air con fan to the cooler? I would have thought that there would be a nice amount of clearance but I guess it depends on exactly how far back you mount the intercooler.

I would try to fit a 14inch davies craig fan on the condensor. I have one of these and it works a treat just as a supplement if you experience stinking hot weather in a little bit of traffic with air con running. I wouldn't think you would need to go slimline. But if you do, then the main thing to look for is the flow rating. Compare the rating of the slimline ones you are looking at with the davies craig 14inch and you will be able to tell if the airflow is comparable.

Anyway, I gotta go Jack. If you need any specific help or info, then you know Im just a SMS or PM away.

Talk soon mate.

Stooge 28-10-09 19:38

Nice build Jack. The car looks hell clean and love the polished calais mags. A factory manual vlct is pretty rare, nice job. 5spdvl is selling a thinner thermo modded to suit the vl loom http://calaisturbo.com.au/showthread...32#post2317632. Also the gktech coolers are supposed to be good for 300+rwkw, so maybe keep urs if u can.

VLWAGONIT 28-10-09 20:03

there is no point him keeping the gktech cooler pipeing cuz hes running a high mount 35/40 and a forward facing plenum so its just easyer 2 sell the pipeing he has and go custom

JET_VLC 28-10-09 20:54

Quote:

Originally Posted by EVL
are you retaining aircon? you will find it very hard to keep cool with big hp, intercooler, a/c condenser and a radiator, especially just using a davies craig fan. I'm on my third round of looking at options at the moment for mine. I've decided again to pull aircon out of this car as it wont be driven during 32+ degree days anyway...

pull the a/c out like EVL said ur not gonna drive it on a 32+ degree day it will just fry

HoldenOn 29-10-09 01:09

Quote:

Originally Posted by JET_VLC
pull the a/c out like EVL said ur not gonna drive it on a 32+ degree day it will just fry

On a hot summer's day 30+ degrees is great weather to go cruising which I do regularly in Summer. Its the best time and I guarantee that I wouldn't go as much in that weather if I didn't have operational aircon.

And there is no reason for a VLT to overheat on a day like this with aircon cranking unless you are flogging the pants off it or your cooling system isn't up to scratch or there is another underlying issue.

Admittedly, it is easier on the engine and cooling in general without the aircon and its associated parts like the condenser and compressor etc......it may even add a horse or two back to the engine, but I know I wouldn't be without my aircon when there is no reason for it not to be there if setup correctly.

TheChad 29-10-09 02:49

Quote:

Originally Posted by HoldenOn
On a hot summer's day 30+ degrees is great weather to go cruising which I do regularly in Summer. Its the best time and I guarantee that I wouldn't go as much in that weather if I didn't have operational aircon.

And there is no reason for a VLT to overheat on a day like this with aircon cranking unless you are flogging the pants off it or your cooling system isn't up to scratch or there is another underlying issue.

Admittedly, it is easier on the engine and cooling in general without the aircon and its associated parts like the condenser and compressor etc......it may even add a horse or two back to the engine, but I know I wouldn't be without my aircon when there is no reason for it not to be there if setup correctly.


whilst i do agree i wont be flogging it in 32 degree heat, thats exactly the point. in 32+ degree heat ill be cruising which is when ill want the aircon on...

i will be doing all i can to retain the aircon. whilst it is messy in the bay i want to retain as many factory options as possible, i hardly ever use the damn aircon but i want it to be there.

JET_VLC 29-10-09 07:57

Quote:

Originally Posted by TheChad
whilst i do agree i wont be flogging it in 32 degree heat, thats exactly the point. in 32+ degree heat ill be cruising which is when ill want the aircon on...

i will be doing all i can to retain the aircon. whilst it is messy in the bay i want to retain as many factory options as possible, i hardly ever use the damn aircon but i want it to be there.

no 1 in there right mind would flog there car in a 32+ degree day.
if you wanna keep it it factroy just put the a/c stuff bck in when u sell it.
and plus just put all 4 windows down an its fine

Gremlinz 29-10-09 10:19

lol maybe in vic that would be enough...

35*C plus through feb and that wont work :)

keep the a/c, on the one that i had i fit a 600x300x100 fmic no cutting with a/c

VLWAGONIT 29-10-09 12:07

keep the ac - most ppl only rip it out cuz it doesnt wrk in the 1st place

keep yours and just make sure ur cooling system is up 2 scratch ( which from the sounds of things it will be more than enough anyway) and ul be rite

EVL 29-10-09 12:39

for me it's an issue of spinning a compresser when my motor is sometimes doing 8500+ rpm. I'll live with the windows down if i get desperate to drive it on a hot day, i've only recently bought my first car that actually has working a/c. Then there's the weight issue & cooling issue. I have all the a/c gear in this time and the motor runs at times 10 degrees hotter than it ever did with my old setup (no a/c). For these reasons i'm removing it, but i'll admit that initially i did everything i could to keep it for the same reason as jack (keeping all factory extras).

VLWAGONIT 29-10-09 12:45

true, didnt think about the whole 8500rpm+ issue lol

but still - on a 40deg + summer day it is realy nice to able 2 roll up with windows and just hit the AC - one of the things i miss about my vt :(

EVL 29-10-09 12:48

yeh thats y i have the vy ute, no 40 degree cruising in the vl lol there's no point

JET_VLC 29-10-09 18:07

Quote:

Originally Posted by VLWAGONIT
keep the ac - most ppl only rip it out cuz it doesnt wrk in the 1st place

keep yours and just make sure ur cooling system is up 2 scratch ( which from the sounds of things it will be more than enough anyway) and ul be rite

lol thats y i dont have 1

genki 29-10-09 18:15

Quote:

Originally Posted by EVL
for me it's an issue of spinning a compresser when my motor is sometimes doing 8500+ rpm. I'll live with the windows down if i get desperate to drive it on a hot day, i've only recently bought my first car that actually has working a/c. Then there's the weight issue & cooling issue. I have all the a/c gear in this time and the motor runs at times 10 degrees hotter than it ever did with my old setup (no a/c). For these reasons i'm removing it, but i'll admit that initially i did everything i could to keep it for the same reason as jack (keeping all factory extras).


bah.

rb30 shouldn't be going to 8500rpm!!!(?)

lol, you hoon chris!

----------------------------------------

I don't think I could think of anything better than a hotted up VL with working aircon, none of my VL's have ever had VL...If you have aircon working, it's something special ;)

Then again, hot weather doesn't really get to me, so if the rest of my VL's don't have A/C, no biggy..got other things to worry about!


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