Jamz_

iTrader: (12)

Looks good so far... take it you will be fitting a bais valve for the brakes? I've done this in my project, so if u need a hand, let me know.

Know your pain with the ABS removal, so much easier once you have the right tools though

Shmerman

iTrader: (14)

Thanks Beef.

James. I have a compbrake bias valve that I am going to fit. Thanks for the offer I just need to T the line together -I have already made up a new pipe from the cylinder to the bias valve.

trails

iTrader: (41)

Whiteline adjustable control arms, AP's and 22B bumper very

But why are you removing the ABS

Shmerman

iTrader: (14)

I have 3 reasons for removing the ABS

1, stop the ABS activating when it shouldnt
2, not sure of the possible issues with the DCCD box
3, Weight saving

On my way home from work there is a hill that i drive down. At the bottom is a stop sign as it join the main road at right angles. The ABS always activates her for some strange reason. I think as soon as it activated it shuts off - Its not the typical thumping you get - This is slowing down from <20mph. The brakes have little/no assist for a couple of seconds while the ABS resets and has resulted in me yanking the handbrake to prevent me running through the stop sign (and into on coming traffic)

I have liitle confidence in the crappy ABS system. If I was on track and this happens, pulling on the handbrake would not be the solution.

Jamz_

iTrader: (12)

I removed my abs due to similar reasons on track... i would be breaking for a corner, then all of a sudden the abs kicked in, and braking stopped and saw me heading towards a field/armco

Now that i have removed the ABS, the pedal is as it should be (nice and stiff, no play in it at all) and i can control the percentage front/rear braking now (it was braked too much on the back last time, and saw the rear end starting to get wobbly)

trails

iTrader: (41)

1. Could that not be a sensor issue?
2. There should be no issues with DCCD, plenty of variants run both.
3. Negligible I'd say...

I always think removing ABS from a road car is a bad thing, you could probably argue the same for a track car because I doubt many people's threshold or cadence braking skills can match an ABS system...

Shmerman

iTrader: (14)

There are too many documented situations that are very similar to mine where they lose the brakes. I don't think it was a sensor problem as I only ever had it happen here.

trails

iTrader: (41)

other than cooking the standard brake set up after a number of three figure stops I've not had any issues with the brakes...just be careful on the road without ABS

Shmerman

iTrader: (14)

There are probably very few circumstances where this ABS issue arrises but that said I know it can happen with my car.

I know what your saying about having a powerful road car that lacks ABS. This has been worrying me for a while.

My other vehicle doesnt have ABS - FWD, diesel and slow. whilst the weather has been bad I have been forcing the car to lock up so that I gain experience of recovering the skid.

I have a skid course booked

Hopefullly this will give me the skills I will need to continue to be as safe as possible on track or the road.



I wouldn't suggest to anyone that removing the ABS is a good idea

Shmerman

iTrader: (14)

The engine is now with my builder as of yesterday. They are going to start work on it soon. Its off to the machine shop to have the block and components check out.


I have been busy getting the car rolling again. I started off with the rear. Remembering how the handbrake mechanism went back together was rather tricky. managed it in the end. The hubs are R180 hubs from a type R and are 5x100 so I had to remove the rear stone guard off the hubs to accomadate the larger discs.







I moved on to the front where I have put the Ap's on and some alloy wish bones. Not had chance to bleed the brake system yet to make sure all my new connections are good.


How the car is now.




I though it would be a good opportunity to clean the engine bay a liitle as it was very dirty. I just used Gunk and a pressure washer.

A couple of before and after shots.













Also trial fitted the new rad. I did start on trial fitting the FMIC but one of the mounting bolts sheered off when i was tightening it so I will have to extract it and run a tap through the thread.

Shmerman

iTrader: (14)

After careful consideration and a chat with my mapper I have decided that I need I should do all I can to help the car breath enough to extract 500bhp from it on just v-power. I dont want the hastle of carrying/storing methanol. I may change my mind and have a meth map at some point but this will probably on be for the track/strip.

I am going to get a standard fit turbo - i'm thinking the SC50 or waiting to see if Mark comes up with something based on the 321v - but will be rotating the turbo.

I am also going to give the STi v3 heads a bit of treatment in the form of some porting, one piece valves and uprated valve springs.

I have a few more things I have picked up along the way

Simtec ECU with anti lag and launch control
Billet fuel rails
800cc flow matched injectors
had the H&S resonated centre section rear flange changed to make it a full 3" system

Shmerman

iTrader: (14)

I have been mega busy recently and not got much done to the car.

The engine is with Steve Cotton being built.

The heads are getting some nice treatment - more on this later when I find out.

Got myself some RCM headers and 3 bolt up pipe. Wrapped the headers - a job I will never do again!!! I would rather pay to have them ceramic coated. I have heat wrapped a few bits in the past but you soon borget what a PITA it is and how itchy you become after.

Adz has been doing some more (fantastic) work for me and I have had the up pipe and down pipe rotated. Realy great job, and a decent price to suit.

I start back at uni in a couple of weeks part time and its going to be very difficult/impossible to get any time on the car.......

I have decided that I am going to transport the shell up to Cotton Competition for Steve to fininsh the project for me. I am gutted about this as I was so close to completing it alone (bar the engine being built up).
I am hoping he will take a few pictures for me along the way to tease me with.

frayz

iTrader: (7)

Cool, best of luck

Shmerman

iTrader: (14)

I decided I wanted to try a different look for the inlet manifold. I had refurbed ny last one red and was happy with it but it doesn't take long before it looks old/dirty again.


The calipers were looking a little tired


After a clean up and a lick of paint they were much better.

beef-on-the-bone

iTrader: (5)

nice touches

Olly.Wrx

iTrader: (10)

Looking really good so far.This will be a monster when its done.

super_ted

iTrader: (30)

good project, i'm following this one.

Shmerman

iTrader: (14)

Thanks guys........olly, nice avatar

Shmerman

iTrader: (14)

The end is near (hopefully)

I have collected a few more things on the shopping list.
Inlet manifold
swirl pot
fuel distribution block
Bosch 044
fuel lines
fuel filter
coil pack mounting bracket
reversed alternator bracket and pully

The inlet manifold is rather special. Its a phase 1 that Andy forrest modfied to take front entry and possible some porting and was on his car for some time. Recently it has been on another car running quite high power so it works quite well.

I have also managed to get this





MD321V

wrathchild_78

iTrader: (3)

Nice thread! Can't wait to see your car finished

Dazza9t9

iTrader: (2)

Nice build, ill be following this too

Shmerman

iTrader: (14)

Thanks wrath/Dazza

I am really looking forward to just driving the things again now. Its been over 12 months since I took it off the road - far to long. It is gonna feel so awesome when its done.

update time....


I have been up to Cott comp today to pick something up from my car.
Also took a couple of pictures of the goodies waiting to go on the car.

cosworth baffle plate


The cosworth oil pump is the 12mm version. I will be retaining the oil squirters and also adding an oil cooler at some point so I wanted the extra capacity.



The head studs are the higher tensile ones (20002440)



ARP block casing bolts


selection of cosworth/arp bearings



There is a slight hold up with the engine build. On the dry build everything was check and given the ok apart from the pistons were protruding slightly above the block.

Looks like some material is going to be removed from the top of the pistons and the heads will now have to be built up (awaiting new valves, springs etc...) and the compression ratio calculated so the correct head gaskets can be ordered.

Shmerman

iTrader: (14)

Had a further delay with the heads getting built as the valve train has been paticularly diffucult to get hold of.

I think I now have the information that I need (thanks to Paul Blamire)and a supplier of what I need - some valves coming from Paul's stock, the rest from the states.

The turbo is with turbo dynamics hopefully getting a new compressor cover as the orginal one was distorted
I will hopefully have that back in the next few weeks then it will be going to Adz's to have the compressor cover rotated and actuator re-mounted and the oil/water lines making up as the turbo is being rotated.

An issue that I wanted to resolve was the induction side of things.
I have gone to the trouble of rotating the turbo to have a straighter inlet tract (not under the inlet manifold) and shorter intercooler pipework. However I dont want to then be sucking in warm engine bay air that is going to lose me power.
Adz's has made a custom air box so that the huge air filter can sit further into the inner wing with a cold air feed but still be protected from water.
He has made up a couple now and is selling them for a very competitive price.

you can see more of them in his project thread here http://bbs.22b.com/cgi-bin/ultimateb...246;p=2#000075

Shmerman

iTrader: (14)

I have looked at doing several things with the heads.

initiall i was going ot leave the heads along and just use stock STi v3.

I then wanted to ensure that they were going to be as reliable as possible. As the stock valves are two piece I was worried about dropping a valve. I think this is a very rare occurance but wanted to err on the side of caution.

The plan was to swap the valves for supertech with duel valve springs and titanium retainers.

Unfortunatly supertech dont make retainers for the v3 heads. This could have been solved by sourcing some retainer that Paul Blamire could have had custom made.

I wanted to check how much more a decent set of cams would set me back.

I called Kent cams about their reprofiling service. They can reprofile the v3 cams to DH22 spec which I belive is a prodrive derived profile that was used in the WRC cars. This was 335+vat. They were unable to what preload I would need on the springs though.

Trying to keep costs down I was thinking of just getting the cams reprofiled and using the stock valvetrain but I read here (again from Pavlo iirc) that this is not a good idea as the material removed from the cams will need to be replaced which usually means new springs etc....

So in the end, a little fed up from going in circals, I decided that I just want the thing build and back on the road - the heads are staying stock V3 STi with vernier pulleys.

As the block and heads have had a skim(s), my understanding is the correct gaskets will bring the compression close to oem but im not sure how close the timing will be. The adjustable pulleys will have the timing spot on

Picked up some RCM verniers


I have got my turbo back from turbo dynamics. This was the MD321V that was for sale on here (Dave Garrett's). When I received the turbo the comp wheel was touching the cover very slightly when rotating. Mark @ lateral did a great job at helping get this sorted so a big thanks to him. I now have the turbo back with a new comp cover as TD discovered that the original one has somehow distorted.

I am in no doubt that Dave has no idea that there was ever an issue with the turbo and has been very good about it all. He has said that he will refund me half the costs of getting it sorted out -




Picked up a nice RCM catch tank. I had been on the lookout for one of these for over 12 months then 2 came up within a month of eachother. I had been looking out for the rectangular one that sits down near the chassis leg but got a hold of this one



Just waiting on the cotton competition to get cracking on the engine now.
Bottom end is now fully built up. Just a case of getting the heads sorted. Valve seats, guides need doing and then put the valvetrain back in and the long block will be complete. Still loads of fab work to be done when the engine is dropped in.

Treated the car to 22b rear spoiler. deliberated on the spoiler issue but as this is the best looking one (on par with the P1)in my opionion I couldn't resist.

Shmerman

iTrader: (14)

The long engine is now built and half dressed. I did have cosworth head gaskets for Tue heads but after a few calculations it wasn't think enough to get a satisfactory compression ratio. An STi 1.6mm was favoured instead.

I have asked to have the car back in time to run at scooby shootout. Fingers crossed.

Shmerman

iTrader: (14)

Not gonna make scooby shootout

Just to much to do on the car and not enough time. Gutted.

a few pictures




and it about to be dropped in

Shmerman

iTrader: (14)

Been to cotton competition today as the engine is now in the car and been cranked to get oil pressure.

The car is now at a point where I just need a few brackets fabricating (fuel distribution block, FPR, locating the catch can for eg) and I want the FMIC pipework as short as possible to help reduce lag. For this I am having the FMIC flipped and running the pipework under the headlights. The rest of the stuff just needs bolting on and it should be ready for a running in map and an MOT/Tax.

The car is now leaving Cotton Competition and going to Adz's workshop for the rest of the work to be done. I am still flat out with my part time MSc working shifts and moving house so I simply donnt have time to get my hands dirty.


Steve, Joe and (forgive my ignorance, the other chap) have done a fantastic job once again. Thanks also to Dave and Richard at cott comp for sourcing the parts required.

Thanks to Brian at CAMS (AKA speedflash) for supplying me with some many parts for the build.

acceptance speach over

should only be a few weeks now and fingers crossed I will be running it in.
A couple of pics I took today.

PontusGT

iTrader: (9)

Looking good!
Have sort of finished my car now and have finally been able to give your old PPG box a testdrive.
Really happy with it! Thanks.

Cheers

Shmerman

iTrader: (14)

That's great news, I'm glad your happy with it. I have to admit I miss the sound that box made.

hhh1234

iTrader: (17)

Any updates