I'm working on the intercooler today. Aluminum shavings are everywhere.

Monday my cylinder head will arrive from ForceFed I'm super excited about that. Then I'll get to check my head flange against their port on both the turbo manifold and the Magnus v5. I'll also show some pics of the porting I did on the internals of the head to help the flow back into the block via the drain backs.

I'm hoping to have time this weekend to mod my water pump for the 4G64 block... and finish up assembling my shortblock, windage tray, and oil pan... so when Monday rolls around I can plop the head on and move towards having an assembled long block.


Here's a couple dyno charts to tide you over. not all these runs are apples to apples, so take them with a large grain of salt.

HKS7460 on E85 vs. stock 9 on 110L


HKS7460 on E85 vs. FP Red on c16


HKS7460 on E85 vs. stock 9 on 92 octane.


BBK Full on Jeremy's Evo 9 versus the HKS7460 on my car.

since u are onto a different setup, what are your final thoughts on the HKS7460?
btw nice build so far

I really liked the HKS turbo except it didn't have an anti-surge cover. I think if I were going to get a stock appearing turbo I would run the BBK-B Ball Bearing Full w/ surge cover...or the BB FP Red with their surge cover.

Just found this thread, thanks for sharing. I'd be happy to build something half as functional as your car.

So I started fabricating my end tanks for my intercooler which I've designed in catia to help me visualize how I go about fabricating them.


Got my intercooler core back on the jack to mock it up.


After fumbling around with a 5" diameter tube trying to reshape it into a 8" diameter tube...after cutting it into a quadrant... I gave up and went to Carslon Steel and picked up some 6" sch10 aluminum tube (which is nearly 7" OD)
NOTE: The Alcoa Aluminum tube in the bin is a 4" diameter tube for reference.




Tacking the pieces together


Welded




Sawzall!




After cutting the end tank I transferred the shape onto a piece of cardboard with a Sharpie. Then I cut out that shape and transferred it to a sheet of aluminum.



Here I formed the piece and trimmed it to fit perfectly in the opening



Zap. Welded it



What the inside of the endtank looks like. You can see how well I fit the pieces up




Here's a picture of the partially modded passenger side end tank and the unmodified driver side.



4G64 assembled shortblock


Transmission and T/C


3.5" Tubing... and a comparison to a 3" aluminum intake pipe.



Fans - 12 slimline and 10" ebay fans.


Exhaust components - 3"-3.5" transition, v-band, and flex pipe.


AN Plumbing - see the huge fuel filter?


Sensors - IAT sensors, MAP sensor, and an oil temp sensor... weld bungs and pigtails.


Kinsler Fuel Pressure Regulator - This guy is expensive, but has the smallest amount of fuel pressure creep! This will be crucial for a dialed in fuel system. Base pressure is set higher than I want to run, but I can leave it... The ID2000's atomize VERY well and do not need 100psi base pressure for them to work well.





Here's the Earls 25 row oil cooler which I have to make a bracket for. I'm not thrilled about this, but it was far cheaper than buying a pre-built kit or buying the OEM cooler. I got this from ANplumbing too. I'll run some Earls prolite hose with -8AN fittings to and from the oil filter housing. I'll have to check, but I think they're 18mm x 1.5 fittings in the oil filter housing.

Also here is my huge 4" tube - K&N filter. This will occupy the space where my ACD used to. I plan to make a little pressurized inlet box that is sealed off from the engine bay. Should be very tedious and time consuming for relatively little to no return.


Vipec v44 w/ extension harness. I wish I would've bought a v88 for more I/O options and the internal knock amplifier. Oh well.


Kiggly HLA. Controls the oil pressure that feeds the hydraulic lash adjusters. Keeps oil in the pan and not in the head. Thanks to Kevin for making such a great product.


GSC S3's. To be replaced in a back to back test with Aaron Spec GSC R2's


Fluidamper - damping the crankshaft is probably a wise investment.


More intercooler madness tomorrow. maybe some water pump mods... maybe some fuel system plumbing.

Beautiful car

great build..

edit: ha, as i was looking through i saw pics of stu hagen's cars.. stu is a great person he did some custom l.e.d work for the interior of my supra...

Yeah Eric, it was a manifold built for Turbonetics wastegates. Big *** flanges they were.

Thanks jwalleg!

Yeah Stu is awesome. When I was getting my post bacc at the VRI, his son (Marshall) and I did the engine development for our FSAE car. I worked with Marshall the past year at Janicki. I've been tuning his Supra for the past few months and trying to coax him to push for 700whp on the Sequential Twin Hybrid 28's. He's such a character... you should've seen how excited he was when he found out he made 600+ in Texas. Marshall edited it out of the video, but I thought it was great. He was fist pumping and had a huge smile. I thought that was pretty awesome. A lot of people knew Stu at TX2K12 and so many people were like "HEY STU THANKS FOR THE AWESOME LED CONVERSION" So it's just funny that I found someone else that had it done He's a true car enthusiast.

I know the one.

absolutely magnificent build thread. Your attention to detail, knowledge of the craft and fab work is outstanding. Sub'd!

Yo I feel like a tool commenting again but your welds are gorgeous. I wish I had 1/1,000,000,000th of the knowledge and hands on that you do man.

very nice, can you post some pics, how you relocate acd pumps tubes from front position to rear? thanks

nice build R/TErnie! great job!!

great thread mate and look forward to more bits and pieces, seeing your car gives me a little insight on what to expect.

Looking good, what size IC piping are you going to run? Im building one of my end tanks like yours but I'm going to weld an internal velocity stack instead of just butting a 2.5" pipe.