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GrooveStyle 12-02-2015 09:07 PM

GrooveStyle's Build
 
Hey guys, I'm on the verge of starting my turbo build, so thought it would be a good time to start a thread outlining my plans and tracking progress on the install of my Gamma V3 Turbo kit. Having had some time waiting for the kit, I had already installed some supporting mods, but not all. See below:

Car:
2012 370z 6MT

Goals:
I'd like to hit 500whp at around 10 psi on pump gas and without building the motor. Haven't seen a ton of data on this kit, but I think I should be able to get into the ballpark? I also want to do all the work myself except tuning. Bonus points if I can do it without dropping the motor!

Already installed (in order of installation):
-Motordyne E370 catback
-Swift springs
-20mm H&R spacers all around
-Whiteline front/rear swaybars
-Defi red racer boost, oil temp, and oil pressure gauges (powered only)
-Custom pillar gauge pod for Innovate AFR gauge (not wired yet)
-ZSpeed Stage III daily clutch kit with 19lb flywheel, HD CSC
-Whiteline diff bushings

Progress from those components were logged on a local Iowa forum:
Luke's 370z Journal


Now for the turbo plans, muahahahahahaaaaa :excited:

Gamma V3 Turbo Kit:
-Turn-key kit
-GT2860RS Turbos, 0.86 turbine housings
-Internal wastegates
-Uprev Tuned

Purchased supporting mods:
-GTR spark plugs (1 step colder than stock)
-Z1 test pipes
-Z1 urethane motor mounts
-48 Row Tru-Cool Oil Cooler / Mocal thermostatic sandwich plate
-Summit fuel pump relay kit
-Greddy Profec OLED boost controller

Lots of pictures to come! :tiphat:

Kit staged to start:
http://i459.photobucket.com/albums/q...psbr04up8p.png

More pics of packaging:
http://i459.photobucket.com/albums/q...ps2upchmjr.png

http://i459.photobucket.com/albums/q...psgapsngoi.png

SwissCheese 12-02-2015 09:12 PM

Aw man, I'm subbing for this!

How much did you end up paying for the kit altogether (with the initial payment plus whatever Gamma charged afterwards)? Also, what's the diameter of the exhaust piping on the Motordyne? Will that need to be upgraded for the turbo kit?

Good luck with everything! Keep us updated!

GrooveStyle 12-02-2015 09:38 PM

Quote:

Originally Posted by SwissCheese (Post 3359008)
Aw man, I'm subbing for this!

How much did you end up paying for the kit altogether (with the initial payment plus whatever Gamma charged afterwards)? Also, what's the diameter of the exhaust piping on the Motordyne? Will that need to be upgraded for the turbo kit?

Good luck with everything! Keep us updated!

Thanks! Soooo I paid $6700+$1500 = $8200 for the kit. It is what it is. Feel like I overpaid given the 2.5 years of effort it took to get it, but after all the frustration, it's best to just keep looking forward.... my wife is still married to me, so I take that as a win.

The motordyne is a progressive exhaust, so it starts at 2.5 and goes to 3". I just have standard test pipes... decided not to spring for a full 3" exhaust since I'm staying in the 500 range. I think it's free flowing enough to get the numbers I want. If I want to go higher I'll switch out for the 3" motordyne turbo tdx midpipe and do a full 3" system I 'spose.

jaytirbhaw 12-02-2015 09:47 PM

very nice, who's doing the ecutek e tune?

GrooveStyle 12-02-2015 10:23 PM

Gamma is. They're planning on doing a full e-tune. Still ironing out their base map. That's why they sent me Uprev initially. I told them I'd wait until they finished their base tune and have them ship me ECUtek instead. Can't pass up launch control and adjustable traction control....

Memphis370Z 12-02-2015 10:26 PM

Sub'd. Good luck with your build!

zguynate 12-03-2015 09:08 AM

You should be able to reach 500whp easy easy. Good luck with everything! I'll be watching this. I want to know how it is trying to do this without pulling the motor.

YzGyz 12-03-2015 12:58 PM

500 should be easy with all that. You are missing clutch kit to sold the power. South Bend it. My SpecZ works but had to do a lot if back and forth fiddling to get it to work right. As for the $ overall, it's more than the initial group buy price but relatively cheap for a TT kit. Then again, you still need sparks but, you get ECUtech.


YzGyz

GrooveStyle 12-03-2015 07:33 PM

Thanks guys. Yeah, I installed a south bend full face kit from Z speed performance about a year ago to get ready for the build. If that doesn't hold, I'll go with a puck style disk. And yeah, all things considered, still not bad for a full TT kit.

SwissCheese 12-10-2015 09:19 PM

Sooooo . . . did you start yet?

GrooveStyle 12-10-2015 10:30 PM

Per the instructions, I realized that you have to do some stuff with the tuning software prior to starting your build. So I'm still waiting to get my ECUtek cable from Gamma, and cannot start. Heard back from them today saying they will ship early next week. Might do the fuel pump relay upgrade or something in the meantime, but pretty much stuck at step 1 till I can get my cable. Once I have that and get the software out of the way I'll be going full-bore. If I get everything ready to start next weekend, I'll take some additional days off to try and crank it out. Too bad, too, since it's gonna be such a nice weekend.

Oh well, I'd rather get sent something that they have confidence in rather than something they kicked out the door that might kill my engine.... Lol

Sounds like Jayhovah and I might be in a turbo-building race this Christmas!

GrooveStyle 12-19-2015 12:35 PM

Quick update. Gamma said that they still haven't figured out the ECUtek tune for the kit, that they were fighting with some errors this week and it may be until mid Jan or so before they nail it down.

I decided to have them just ship me the uprev cable back now so I can get started. It should arrive on Tuesday. I'd rather get started on the kit and have a base tune that I can have some more confidence in than something brand new that has been causing issues. I may switch over to ECUtek at some point when it's more widely adopted, but I think that uprev may be nice to have since I can adjust parameters myself and also don't have to Etune everything or drive 9hrs to Louisville for the closest tuner.

Tuesday night, gonna get started! (for real this time)

GrooveStyle 12-30-2015 07:46 AM

Ok, sorry I haven't been posting yet, had some great progress but long last two days.

Day 1 - 12/23
After getting my base tune for uprev late the night before, I was able to get started. I had a few hours before I had to leave for holiday stuff. Got as far as the intake manifold removed and called it for the day:
http://i459.photobucket.com/albums/q...psjtvk1awp.png

http://i459.photobucket.com/albums/q...psxkpfwy57.png

Day 2 - 12/28
This was the teardown day. Got the bumper, crash bar, power steering lines, windshield washer tank, air cleaner ducts, cats and headers off!

http://i459.photobucket.com/albums/q...psy6khy5sz.png

http://i459.photobucket.com/albums/q...psxzltmq69.png

I also installed the Z1 urethane motor mounts. They are supposed to be height adjustable, but I don't think they were able to give me the full 6.25 mm of lift that I needed to compensate for the supplied spacers. In the end I used the motor mounts at stock height with the engine mount spacers. Overall things went pretty smoothly:

http://i459.photobucket.com/albums/q...pssockcqfc.png

Day 3 - 12/29
Now things get interesting. I heeded Jayhovah's advice on pretty much everything he's said in his build thread, and things have worked out pretty well in my favor so far. It was slow going, but I installed the fuel line extension first, then the heater hose, then the heat shields onto the exhaust manifolds, and then the manifolds into the car.

http://i459.photobucket.com/albums/q...pswq3sli3c.png

It took a fair amount of bending and tweaking of the water pipe on the driver side to get wrench clearance to the manifold nuts.

The passenger side had it's own issues, requiring the removal of the black plastic electronic box that holds the main harness to get clearance between the wires and the manifold. I ended up removing the box and heat wrapping the harness (Jayhovah confirmed that this is standard practice as per Gamma tech support).

http://i459.photobucket.com/albums/q...psspzctgkb.png

I also had to remove the rear two engine studs to get the passenger exhaust manifold on, then put them back in with the manifold in place. Man, those manifolds are tight in there! Should be good now.

I ended the day with the headers on, but not torqued.

SwissCheese 12-30-2015 09:07 PM

Sounds like you've had a busy few days! Reading all that makes me realize that I would have no idea wtf I would be doing, lol.

GrooveStyle 12-31-2015 08:43 AM

Day 4 - 12/30

Holy crap the clearances to some of those exhaust manifold bolts are tight! I had to get a little creative to get one nut on the driver side (proud but not proud of it at the same time):
http://i459.photobucket.com/albums/q...psvbbgmgz2.png

Should give me points for creativity, right? getting the manifolds on and tight took a while, but I was able to get the turbos prepped and the passenger turbo mounted:

http://i459.photobucket.com/albums/q...ps6jofbzwc.png

http://i459.photobucket.com/albums/q...psvnhumlnp.png

A buddy of mine stopped by to check out the build and gave me a hand with getting the passenger turbo bolted up. Going to take care of the driver side turbo and do plumbing for them next!

GrooveStyle 01-02-2016 08:10 PM

Update time!

First off, congrats to Jayhovah on the finishing of his kit today! Hats off to him and his brother in law being the first to tackle this kit as a DIY! I chatted with them briefly on the phone a few times, super awesome dudes. If we ever get the chance to meet up, I'd like to buy you a few beers. Thanks for all the help. I'm truly grateful for this awesome 370z community!

Day 5 - 12/31

Day 5, I got the driver side turbo on and tightened up. Took some careful maneuvering to get the nuts all tightened up, but at this point I was feeling comfortable with tight spaces.... hah!

http://i459.photobucket.com/albums/q...psys6p0eur.png


My process for the front nuts:

Hold like so:
http://i459.photobucket.com/albums/q...psmywdqmsu.png

Jam your hand all up in there:
http://i459.photobucket.com/albums/q...pspq33jdxl.png

Then finish with speed wrench/crowsfoot.

I also shielded the braided hose lines from rubbing harnesses/hardlines:
http://i459.photobucket.com/albums/q...psboxd3b7s.png

http://i459.photobucket.com/albums/q...psmuvewjpg.png

Happy little turbo all mounted
http://i459.photobucket.com/albums/q...ps5vgsjoj0.png


I plumbed coolant lines as well:
http://i459.photobucket.com/albums/q...psnyft2edm.png

http://i459.photobucket.com/albums/q...psx9eobrep.png



Day 6 - 1/1

Spark plugs, injectors, wrapped harness that had mouse damage from this fall :(

Harness before:
http://i459.photobucket.com/albums/q...ps0nlp5nnf.png

After: :tup:
http://i459.photobucket.com/albums/q...pssmjdwnzv.png

Installed the Gtr plugs that are 1 step colder than the OEM 370z ones (NGK DILKAR8A8):
http://i459.photobucket.com/albums/q...pseklmxlky.png

I didn't have a spark plug socket, but my craftsman 14mm deep socket and a magnet did the trick:
http://i459.photobucket.com/albums/q...psbnefdlgr.png

http://i459.photobucket.com/albums/q...psembeusap.png

Injectors swapped:
http://i459.photobucket.com/albums/q...psrtdenfi3.png

Torqued up:
http://i459.photobucket.com/albums/q...ps0djkygrh.png

And I spent the rest of my evening trying to come up with a game plan for my oil pressure sensor and doing turbo oil line routing. There is an available port on the oil distribution block that they give you, but it faces directly toward the OEM oil temp sensor. I picked up a 90 deg elbow and am going to give that a try next.

I took the day off on 1/2 to hang out with the wife and take care of some other stuff around the house. Gonna get back at it on Sunday!

To do list:
Finish routing oil lines
Add more heat wrapping on the main harness / fuel lines
Drill/tap/install intake manifold
Route IC piping
Mount intercoolers
Tap pipes for PCV plumbing
Mount driver side wastegate
Vacuum line routing
Power steering mounting/line hookup
Install oil pan
Install downpipes
Install test pipes (and O2 sensors)
Fuel pump install
Boost controller install
AFR gauge Install
Boost gauge plumbing
Oil Temp plumbing
Oil cooler bracket fab and hose fab

Fill fluids (oil, coolant, power steering)
Flash ECU
Start/check for leaks
Wait for the snow to melt!

All in all, I feel like things have been going along rather smoothly, thanks to Jayhovah and his BIL's tips on a few things! :driving:

Jayhovah 01-08-2016 03:10 PM

Just found this thread! And here I thought you were being lazy with no build thread (I was looking for it to pop up in FI subforum). Awesome progress! You are making us look like a couple of amateurs!

GrooveStyle 01-08-2016 10:40 PM

Hah! thanks! yeah, I have some updates to do... I'm back at work now, so I don't have nearly as much time to work on it. I was able to finish routing the oil lines, the heat wrap the remaining components on the passenger side, connect my fuel line, drill/tap/install my intake manifold, mock-up the IC piping and mount the intercoolers though.

I'd like to try to get the bulk of everything else done this weekend if I can, but it's just gonna be pretty dang cold, so I'll have to play it by ear. Keep an eye out for a better update soon. I'll have more pics too, I promise. :driving:

Ty99 01-09-2016 11:08 AM

Good luck, it's soooo cold out here in Des Moines.

GrooveStyle 01-10-2016 10:01 PM

Quote:

Originally Posted by Ty99 (Post 3384715)
Good luck, it's soooo cold out here in Des Moines.

Thanks! yeah it's downright frigid here... didn't get a chance to do as much as I'd hoped this weekend, but here's this week's recap:

Finish routing oil lines: Got those done. Had a bit of trouble with the proximity of all the plumbing, though. The oil distrubution block is really great in that it connects both turbo oil lines and the OEM pressure sensor together with yet another threaded hole for your own oil pressure gauge. I installed a Defi red racer gauge as one of my three in the cluster (boost, oil pressure, and oil temp) and that looked like the ideal place to connect it. However, the hole is perpendicular to the OEM oil temp sensor. So to make everything work, I picked up a 90 deg fitting and plumbed it up. I realize this isn't perfect, but works in the available space. For people that haven't tried this before, I DID try to index the oil dist block to clear the oil temp sensor, but the casting would cause an interference to the Defi pressure sensor in any other orientation. Pic below:
http://i459.photobucket.com/albums/q...ps1mifccat.png

Add more heat wrapping on the main harness / fuel lines: I bought some of the fiber-based wrap and put that around my heat taped harness for good measure. After looking at pics of Jayhovah's setup as well as Gamma's, I figured I should do the same. I ended up heat wrapping the plate by the fuel line with extra heat tape I had for good measure. If anything, just hoping it will help reflect some heat.
http://i459.photobucket.com/albums/q...pscnt7qp4l.png

Drill/tap/install intake manifold: This was definitely one of the more intimidating things for me to do than most of the project. Drilling and tapping into plastic was a concern, but just like everything else, go slow and take your time and it will work out ok. I verified the tap location with Jason at Gamma and went for it. Anywhere on that raised flat surface where the brake booster connect works, just make sure you have hose clearance. I then bolted that puppy back on and connected all the hoses to the manifold.
http://i459.photobucket.com/albums/q...psnqr4dajv.png

Route IC piping: This is, an adventure. I, unlike Jayhovah, had two of the same air intake pipes. Gamma confirmed that the short end of the pipe goes into the driver side turbo, and the long end goes into the passenger side. That worked out for the most part. I mocked up the rest of the pipes (no clamps), snapped this sweet pic then went on to drill and tap my intake pipes.
http://i459.photobucket.com/albums/q...psxme3ervm.png

http://i459.photobucket.com/albums/q...psejwfp2ge.png

Getting everything to fit up properly brought up some areas that needed thought/work. I had to bend my mount for temp? maybe? by my radiator to fit my intercooler

http://i459.photobucket.com/albums/q...ps5gunje2r.png

I also had to get rid of these supports. There was no way the IC's were going in otherwise. Drill out a rivet and take some bolts off. Supports!?! We don't need no stinking supports!! (it's only supports the hood latch... we're good, right?)

http://i459.photobucket.com/albums/q...psivuru2fl.png

http://i459.photobucket.com/albums/q...psl3ahaikd.png

Also, this wiring harness:
http://i459.photobucket.com/albums/q...psnipzmvul.png

Not quite sure on the game plan for this guy... I pulled off the bracket to give them some more slack. I'm going to try and tuck them under the piping, we shall see. I'm open to suggestions. When it comes to this IC piping, it seems like it just touches/rubs EVERYTHING. I wish I could give more clearance, but there just isn't much there. Jayhovah, kinda curious to see some shots of your engine bay to see what all you did / how you routed everything.

Like this, for instance:
http://i459.photobucket.com/albums/q...pszpj0nlia.png
This is a shot of the driver side water line sitting above the connector for the O2 sensor. preeeeetty tight. I haven't been able to get the clip loose yet and reroute, and I don't think I can connect it as-is without doing a serious amount of shoving stuff around! heh. I've learned so much from this build. It's amazing how all this stuff has been able to fit into the engine bay of a 370z.

Here's what I've got left:
http://i459.photobucket.com/albums/q...psmidq7gzo.png

I asked about recommended setting for the BOV's from Gamma, they said to turn it all the way on hard, then back it off 3 full turns. Got those set and ready to go now:
http://i459.photobucket.com/albums/q...pshqheg2ih.png

(oh yeah and I put my driver side wastegate on too, no cool pics of that)

I think that's the highlights of things I found interesting/useful so far. Here's what's yet to come :

Finish clamping IC piping & remove material for 90 deg coupler fitment by IC uppers
Power steering mounting/line hookup
Install oil pan
Install oil drain hoses
Install downpipes
Install test pipes (and O2 sensors)
Fuel pump install
Boost controller install/plumbing
AFR gauge Install
Boost gauge plumbing
Oil Temp plumbing
Oil cooler bracket fab and hose fab

Fill fluids (oil, coolant, power steering)
Flash ECU
Start/check for leaks
Wait for the snow to melt! :tup: :driving:

Jayhovah 01-11-2016 02:11 PM

Quote:

Originally Posted by GrooveStyle (Post 3385347)
Route IC piping: This is, an adventure. I, unlike Jayhovah, had two of the same air intake pipes. Gamma confirmed that the short end of the pipe goes into the driver side turbo, and the long end goes into the passenger side. That worked out for the most part. I mocked up the rest of the pipes (no clamps), snapped this sweet pic then went on to drill and tap my intake pipes.
http://i459.photobucket.com/albums/q...psxme3ervm.png

http://i459.photobucket.com/albums/q...psejwfp2ge.png

Your turbo inlet pipes were the same? I don't even know what to think! Did you confirm with Jason that you are OK like that?
Quote:

Originally Posted by GrooveStyle (Post 3385347)
Getting everything to fit up properly brought up some areas that needed thought/work. I had to bend my mount for temp? maybe? by my radiator to fit my intercooler

http://i459.photobucket.com/albums/q...ps5gunje2r.png

I did the same =)

Quote:

Originally Posted by GrooveStyle (Post 3385347)
I also had to get rid of these supports. There was no way the IC's were going in otherwise. Drill out a rivet and take some bolts off. Supports!?! We don't need no stinking supports!! (it's only supports the hood latch... we're good, right?)

http://i459.photobucket.com/albums/q...psivuru2fl.png

http://i459.photobucket.com/albums/q...psl3ahaikd.png

Yup.. Did the same. I also worry about this.. my intercoolers press against the latches a little as well.

Quote:

Originally Posted by GrooveStyle (Post 3385347)
Also, this wiring harness:
http://i459.photobucket.com/albums/q...psnipzmvul.png

Not quite sure on the game plan for this guy... I pulled off the bracket to give them some more slack. I'm going to try and tuck them under the piping, we shall see. I'm open to suggestions. When it comes to this IC piping, it seems like it just touches/rubs EVERYTHING. I wish I could give more clearance, but there just isn't much there. Jayhovah, kinda curious to see some shots of your engine bay to see what all you did / how you routed everything.

Yeah those harnesses get in the way of the pass charge pipe. We were able to keep them in that plastic bracket/holder, but the top cable went over the charge pipe and the bottom one went below. Text me I can get you a pic if you need.

Quote:

Originally Posted by GrooveStyle (Post 3385347)
Like this, for instance:
http://i459.photobucket.com/albums/q...pszpj0nlia.png
This is a shot of the driver side water line sitting above the connector for the O2 sensor. preeeeetty tight. I haven't been able to get the clip loose yet and reroute, and I don't think I can connect it as-is without doing a serious amount of shoving stuff around! heh. I've learned so much from this build. It's amazing how all this stuff has been able to fit into the engine bay of a 370z.

That clip is a sonofabitch. We heat wrapped the o2 cable and the coolant feed and clocked the feed fitting toward the chassis.. the line barely clears the plastic connector, I am sure they kiss from time to time but the heat wrapping is soft. I think Jason also recommended we can just take those clips off the positioning tabs and leave the connection to float. We ended up doing that on the passenger side.. We couldn't find the positioning tab and figured it must have come off with the harness cover. =)
Quote:

Originally Posted by GrooveStyle (Post 3385347)
Here's what I've got left:
http://i459.photobucket.com/albums/q...psmidq7gzo.png

I asked about recommended setting for the BOV's from Gamma, they said to turn it all the way on hard, then back it off 3 full turns. Got those set and ready to go now:
http://i459.photobucket.com/albums/q...pshqheg2ih.png

Should be good! We did 4 full turns since you can only do 8 turns before the spring launches the cover into outter space (found that out the hard way) and so we figured half way should be good. We asked Johnny during tuning and he said they were working well and didn't need any adjustment. I love how the manual says "adjust per manufacturer instruction" and the Turbosmart manual gives no guidance.

Quote:

Originally Posted by GrooveStyle (Post 3385347)
(oh yeah and I put my driver side wastegate on too, no cool pics of that)

I think that's the highlights of things I found interesting/useful so far. Here's what's yet to come :

Finish clamping IC piping & remove material for 90 deg coupler fitment by IC uppers
Power steering mounting/line hookup
Install oil pan
Install oil drain hoses
Install downpipes
Install test pipes (and O2 sensors)
Fuel pump install
Boost controller install/plumbing
AFR gauge Install
Boost gauge plumbing
Oil Temp plumbing
Oil cooler bracket fab and hose fab

Fill fluids (oil, coolant, power steering)
Flash ECU
Start/check for leaks
Wait for the snow to melt! :tup: :driving:

Make sure you SCRUB that oil pan clean! Ours had a little casting dust left in there... Also one of the screws on the baffle was cross threaded :confused: which I found annoying. I reinstalled with thread lock per the manual so I feel OK about it.

Feel free to text me for any pics you may need.. If they are easy to take (top of the car) I can get them pretty quick if I am near the car... anything else I'll have to sift through our huge bucket of pics to find one to send =)
I remember most of the hiccups though, so I can usually describe it at the least!

jwick 01-11-2016 02:37 PM

Nice work!

GrooveStyle 01-11-2016 09:18 PM

Thanks! And thanks Jay for the feedback. I'm glad we're thinking the same way! I'll be sure to scrub down that oil pan. And yeah, Jason said that there were two sizes of those turbo inlet pipes, one would only work on one side, but the other could work on both. I've made them work, so I guess I'm good? :D

Jayhovah 01-11-2016 09:23 PM

Quote:

Originally Posted by GrooveStyle (Post 3386302)
Thanks! And thanks Jay for the feedback. I'm glad we're thinking the same way! I'll be sure to scrub down that oil pan. And yeah, Jason said that there were two sizes of those turbo inlet pipes, one would only work on one side, but the other could work on both. I've made them work, so I guess I'm good? :D

You are good!

I'd guess they sent you two drivers sides. The drivers side was the one we could only get with the correct pipe in the correct orientation.. The passenger side we could get with either pipe in either orientation =)

carlitos_370z 01-12-2016 01:39 PM

nice work dude! subscribed to see the final results :tup:

///maestro 01-13-2016 12:25 PM

good stuff man, I applaud people that tackle on projects as big as this. Do you have any prior mechanical knowledge or doing this with the help of a friend?

carlitos_370z 01-13-2016 12:32 PM

Quote:

Originally Posted by ///maestro (Post 3387404)
good stuff man, I applaud people that tackle on projects as big as this.

:iagree:

theDreamer 02-11-2016 11:44 AM

Looking good, let me know when you are done & I will add you to the finished builds thread: http://www.the370z.com/forced-induct...ed-builds.html

SwissCheese 02-11-2016 09:20 PM

Yea, hows about an update? You have it all finished yet?

GrooveStyle 02-11-2016 10:15 PM

It runs, leaks have been checked. I've heat cycled it up to 180deg oil temps twice. AFR and boost controller are hooked up. I've been meaning to post a proper update, but with work and recent events I haven't had the time.

Planning on posting this weekend, videos and all. Hopefully with highs above freezing next week I will be able to get it on the road the following weekend? All I've been able to do is fire it up in the shop, make sweet engine noises and huff exhaust fumes getting it to temp. Gotta love test pipes! Hah! More to follow..... All I have left to do is put the remaining body panels on, tidy up some wiring, and then do interior work. I want to redo my A pillar and build a gauge mount in my cubby for my EBC.

GrooveStyle 02-11-2016 10:23 PM

GrooveStyle's Build
 
And thanks Carlitos and Maestro. I have done exhaust, springs, swaybars, triple gauge swap, and the clutch/flywheel before tackling this project. The tech manual is an amazing thing that will help to negate fears of working on your car. I also had help with Jayhovah giving a heads up on possible problem areas. Other than that, I've had some basic mechanical knowledge as I work on transmissions for my job. I never worked on a car before working on my Z.

All in all, though, I think anyone can work on cars. You just need to be willing to put in the time, effort, research, and money to do it right. If you can do that, sprinkle in some beer drinking and cussing at the correct times, you can tackle anything. Just take your time and be organized.

GrooveStyle 02-14-2016 09:46 PM

UPPDAAYYTTEE!!! :tiphat:

Let's get to it!

Finish clamping IC piping & remove material for 90 deg coupler fitment by IC uppers

I took my dremel to my radiator support to allow for clearance for the couplers
http://i459.photobucket.com/albums/q...ps8svgn097.png

I have some contact with my radiator hose and the IC piping, I'll be sure to keep an eye on that. I also better tightened down that coupler after this pic
http://i459.photobucket.com/albums/q...psis33hwqy.png

I also found close contact with the passenger side air filter, so I removed some plastic that protruded towards it
http://i459.photobucket.com/albums/q...psvw1ajgdn.png

http://i459.photobucket.com/albums/q...pseq5pcvvw.png

After getting the IC piping fitting well, I removed the from IC's to allow for work on the power steering cooler and oil cooler, and then went to install the downpipes.

O2 sensor connection on the driver side was very tight to water line plumbing, but got it to work with the help of a buddy.
http://i459.photobucket.com/albums/q...pslecrom1s.png

Then I went on to tighten down the locknuts on the downpipes. Got creative again, using a ratchet with a crow's foot on it
http://i459.photobucket.com/albums/q...pssn33zign.png

and yet more creative for places that didn't allow for a ratchet due to the passenger side fuel line heat shield
http://i459.photobucket.com/albums/q...psrgldgn5n.png

I then began fabrication of oil cooler brackets to hold up my 48 row tru cool oil cooler and beefy oil lines I had made
http://i459.photobucket.com/albums/q...psy7iitcgh.png

I made a sort of strap to go across the top, and a u-shaped bracket on the bottom. Definitely not the prettiest, but it functions fine and looks good once installed. I have measurements that I can pass along to anyone interested in making some for their cooler. Feels really solid.
http://i459.photobucket.com/albums/q...psqtcyglry.png

locking nut hardware I used
http://i459.photobucket.com/albums/q...pszuby7asn.png

trial fitting
http://i459.photobucket.com/albums/q...psq56fmri5.png

it was too cold to properly paint the brackets. First time I tried to shoot the paint was all sputtery (learning moment). I'm not gonna wait till spring to tear it all apart again and paint during nice weather, so I set them in front of my space heater and the parts under my halogen lamps. After they warmed up, it sprayed just fine

http://i459.photobucket.com/albums/q...psz2urbhad.png

While the paint was drying, I started work on the oil pan.

http://i459.photobucket.com/albums/q...psyvoh85sw.png

I washed it out the day before and got the metal dust/flakes from the casting removed, reinstalled the baffle and loctited it in.

Surprisingly enough, getting that oil pan off of the car took an incredible amount of force. Nissan must use some hulk-level strength RTV, it was really weird. After a fair amount of prying and working it with a pry bar, I got it off.
http://i459.photobucket.com/albums/q...psgnw92zue.png

pan:
http://i459.photobucket.com/albums/q...pszkk4sh6c.png

I thought I was over the hill after getting it off, but that OEM oil cooler caused some issues with fitment to the oil pan. It was close, but the oil pan would contact it a little bit.

http://i459.photobucket.com/albums/q...ps1ne8wnb7.png

I tried bending the tubing a little, but ultimately I ended up shoving the pan on and progressively tightening the bolts until the oil pan mated properly. This bent the oil cooler more, but at least this caused it to bend in all the correct places to allow the hammer head pan to be installed.

http://i459.photobucket.com/albums/q...psuf2vb2c0.png

After the pan was trial-fit, I put RTV on and bolted it up. The drain hoses followed.
http://i459.photobucket.com/albums/q...psnkjmqqoy.png

http://i459.photobucket.com/albums/q...ps95hd3l47.png

The oil cooler brackets were then dry. Don't they look purty?
http://i459.photobucket.com/albums/q...psyq6afjen.png

Oil cooler installed
http://i459.photobucket.com/albums/q...psvfpkzlsz.png

You can see my mounting points really easily here. I used the two bolts on the far right and drilled a hole in the support in the center for the top strap. The u-bracket sits in the holes of the lower support

I've heard heard many people have had success with home-made hoses, but I've heard one too many horror stories about failure of oil lines for me to feel comfortable making my own. I went to the local Napa and had them make me some lines out of their high pressure hydraulic line. I KNOW this is overkill. The store owner said that the lines should outlive the car. I told him that was the idea!

http://i459.photobucket.com/albums/q...psh0tzfktt.png

Then I pre-filled my oil cooler and hooked up the hoses. Good to go!
http://i459.photobucket.com/albums/q...psmnoa0ne3.png

Pic of the hoses hooked up to my Mocal sandwich plate
http://i459.photobucket.com/albums/q...psjvt85m9h.png

With that done and out of the way, I moved on to the power steering hoses. Got them on to the cooler
http://i459.photobucket.com/albums/q...psrmvitxbl.png

A quick shot of the passenger IC and Oil cooler.
http://i459.photobucket.com/albums/q...pswi4040vw.png

That's the only time I can show it off. Once the driver's side IC is on, it's really sandwiched in there
http://i459.photobucket.com/albums/q...psutbvohwz.png

Oh yeah, I had to bend the horn bracket a little bit to fit it back on
http://i459.photobucket.com/albums/q...psc9yjdh2l.png

Then I moved onto the fuel pump!
http://i459.photobucket.com/albums/q...psp42wpw3b.png

Removed
http://i459.photobucket.com/albums/q...psmyec16sa.png

I thought the fuel level sensor was cool. Never saw one up close before. The float is attached to a wire that rides along this area:
http://i459.photobucket.com/albums/q...psbch5vy7g.png

Here's the new fuel pump ready to go in. It came with a sleeve to hold it in the pump.
http://i459.photobucket.com/albums/q...psbwdh6uyl.png

I had to remove some plastic in the pump, but didn't want plastic particles from a dremel. Turns out a sharp knife will cut out the plastic quite well
http://i459.photobucket.com/albums/q...ps7etfuksd.png

I did some wiring, and the pump was complete
http://i459.photobucket.com/albums/q...psui0hczoa.png

ready to go back in
http://i459.photobucket.com/albums/q...ps2hjnashs.png

I connected my steering shaft coupler, and noticed that my oil drain line was very close to the shaft, as was my coolant line. I cut the oil drain line a little more to make sure that there was always clearance to the steering coupler
http://i459.photobucket.com/albums/q...psauwtceh9.png

Then test pipes went on
http://i459.photobucket.com/albums/q...pssow387ox.png

http://i459.photobucket.com/albums/q...psamue8cb4.png

And I was pretty much done in the engine bay besides sensor wiring.

I had already run my gauges for my triple gauge cluster (defi red racer boost, oil pressure, oil temp), but I still needed to set up my AFR and EBC. I decided to tap into the power for the passenger 12V lighter and use an already established ground by the cabin air filter.
http://i459.photobucket.com/albums/q...pssnmsfbuv.png

http://i459.photobucket.com/albums/q...psrhnfeath.png

http://i459.photobucket.com/albums/q...psp5nsn8fm.png

I'm going to save you the details of all the soldering and wiring.... but it was kinda involved. Long story short READ BOTH THE INSTRUCTIONS FOR THE GAUGE AND FOR THE SENSOR. I thought they were one in the same, but the wires for the gauge harness do not match up with the colors to the main harness..... I also was not shipped instructions for the gauge. It wasn't until trouble-shooting my weird afr values that I discovered this. Just read both manuals 5x and you'll be good.

Here is my chaos:
http://i459.photobucket.com/albums/q...psdutyiznp.png

I drilled a hole in my cubby to feed the wire to my Greddy EBC and fed the boost controller through.
http://i459.photobucket.com/albums/q...pswowpvpf6.png

http://i459.photobucket.com/albums/q...psdauxunb0.png

Since I had a boost gauge already and now have a boost controller, I needed to hook up my vacuum reference to both gauges. I mounted them in the wall of my battery compartment together.
http://i459.photobucket.com/albums/q...ps5b9ndo1c.png

http://i459.photobucket.com/albums/q...ps2hsahuzq.png

I also had my buddy Jon over and he made a bracket for the boost solenoid and we mounted that outside of the batt compartment (i need to add a pic here)

It actually all worked really well. I also cut a hole in that wall to feed a vac line and another on the top of the wall to feed my AFR O2 sensor wire. I think it turned out quite nice.

I also got my CJM Fuel pressure gauge in the mail! Very easy to install, looks great, great price, fast shipping. Check it out, it'll be great to help when tuning.

http://i459.photobucket.com/albums/q...psnle91g4h.png

Before:
http://i459.photobucket.com/albums/q...pswyphoni2.png

After:
http://i459.photobucket.com/albums/q...psefy7vhfp.png

http://i459.photobucket.com/albums/q...pscdcsqp3e.png

After that was all working, I filled my fluids, flashed my tune and was ready to fire her up! :happydance:
http://i459.photobucket.com/albums/q...pskwfuhyim.png

Videos are coming, having issues uploading them currently. Anyone have any questions? Things they want to see? I still have some buttoning up to do, this is a great time for me to show what I've done if you're looking for any additional info/pics.

I will finish my cubby up, finalize my A-pillar mount, and do some further tidying up. Should be on the road doing some data logging once this snow clears off. :driving:

Jayhovah 02-15-2016 02:01 PM

Great stuff luke!!!!!!

Have you refitted the crash bar yet?

I literally haven't turned a screw on my car yet since I drover her home from Texas... first on the list is still to get that crash bar fitted properly. I am dubious that it will fit, but Gamma has sent me the proper hardware.

GrooveStyle 02-15-2016 09:38 PM

Thanks! yeah, I used the aluminum spacers in between the bolts and the bar (which Gamma shipped in a later shipment). It allows for the crash bar to be re-assembled, not a lot of engagement on the nuts, but enough.

jwick 02-15-2016 10:05 PM

That's quiet an update post:tup:

Nyght 03-10-2016 06:11 PM

Subbed for updates ! I will be installing my kit soon !


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SwissCheese 03-10-2016 08:45 PM

"Videos are coming" he says a month ago . . . :rolleyes:

GrooveStyle 03-10-2016 09:39 PM

Yeah, yeah I know.... lol.... I've got to reflash an updated ROM I've received from Gamma today, and I'm going to try to get it on the road this week if I can. It was throwing the P006a code which was causing some issues. This new update should fix it. Haven't gotten it into boost yet, but hopefully this week....

GrooveStyle 03-10-2016 09:42 PM

And yeah, Nyght, let me know if you have questions, I'd be happy to share/help in any way I can.

killrain 03-10-2016 10:11 PM

Awesome thread/build. But after seeing all this, think ill stick with the Stillen supercharger. :driving:


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