Season is over and the car is laid up for the winter...

Easy project that has annoyed me - lack of a trunk floor panel. Previous owner disposed of the original - shipping one is crazy expensive. So local hardware store has something very similar...few hours of tedious cutting and fitting and cutting...it works!

 

Nicely done! I want to do this to mine, it's a bit saggy and soft from water leaking in the trunk.

 

RobbieOh: Thanks!Early Christmas present - HKS Super Drager Exhaust! UK vendor was selling an open box example...box was dated 2002!:


Full cat back that will tuck up tighter:


And quieter...hopefully especially at cruise thanks to the Japanese noise certification:

An example of EU import taxes...since UK is no longer within the EU, we had to pay 30% to Germany ($220) compared to zero just a few years ago.

We will see if the smaller diameter, curvy nature, and quieter system will sap some of the ~400 CHP...may have to upgrade elsewhere to maintain the current thrust...

 

Knowing that the young student will be attempting to manipulate this thrill ride - a softer, gentler clutch with heavier flywheel was procured:

ACT HDSS single disc with sprung hub to allow some forgiveness on shifts (compared to twin disc with no springs):


And 11 pound flywheel to enable easier 'step off' starts (compared to nearly nothing currently with the Cusco unit):


Hopefully will begin the teardown this weekend...

 

Bit of brake bleeding on-going:


Calipers have held up nicely to the track miles - although I'm pretty easy on brakes...

 

Moving on to more fun maintenance actions...repacking axle joints along with new boots:

Old:


New:


Unsure when they were done last and last year one split on the way home from Spa...

 

Both rear axles complete and reinstalled. Moving on to the Ohlins spring 'upgrade'... Many buy a new set of springs for the front typically 100's and swapping with 120's. Then taking the 100's and installing in the rear - bumping both ends similiarly or so we thought. Upon disassembling a front and rear for the exchange, noticed both were 90's. So the rears will not receive any more stiffness. Hopefully, it won't lead to excess understeer. We'll see!:

120's - Note, we paid $50 import tax on these from the UK...making these very expensive springs. Can thank the BREXIT for that...US is very lucky to avoid this 30% upcharge on everything!:



Complete!


I also elected to replace the front wheel bearings - bit disappointed as the are OEM and its not like we did too many jumps or curb hops...;-)


New, shiny parts!

 

More work done this weekend - love repacking axles joints ... but they are complete!:


Notice unusual wear marks on the inside of the left front axle...the same one under hard corning we would get a clicking...hmm. Supposedly it is an internal transfer case issue...we are investigating!


Pulled the lower engine mounting frame out (north/south bar)...replaced the rear engine mount-easy enough!:


Extracted the transfer case - plan to disassemble a bit to see if we have loose diff bolts (?):


Fresh transfer case seal - since I have one:


And swapping the other bearing to keep it even up front:

 

Free time on a Saturday means Evo time...installed fresh front sway bar endlinks (inexpensive OEM parts!):


A new alternator as the original has a bearing squeel until warm...unsure when it is going to take a siesta (appears an Evo 9 model is a straight bolt in for a 5):


And the car seems to be missing a transmission:


It is now on the ground...not terribly difficult...but reinstall is twice has challenging...especially in crocs and solo:


The twin disk that came with the car looks no worse for wear...just a bit too serious:


Hopefully it will go back together quietly tomorrow...it will be a Sunday and in Germany that means no noise/work (I consider this fun so...we'll see if I get reported!)

 

Is this a clean bellhousing or what?:


Simple Green and toothbrush after 10 mins...rinsed with Brakeclean!

 

Any plans to remove the SAS, have my V and contemplating to remove it.

 

huzzle101: My initial thought was to do so especially if we move to an aftermarket exhaust manifold, but since we have hit our power goal, the car is more unique to leave it in place even with the Link ECU that does not activate the system. Besides, if we take it off, we'd lose all the parts eventually! ;-)Maiden voyage...resulted in a mild clunk (loosened strut mount) and big smiles!:


Put 60 kms on the machine and was reminded why these cars are so much fun with the peppy engine with turbo powerband, fun noises and now easy to drive single disk clutch!

Lots of color going on...had neglected to get a new set of pads for the new front rotors...come to find out we are running a basic Stoptech pad - costing 50 bucks a set! Admittedly, I don't work brakes hard...even the powdercoated Brembos look like new:


Friday, we've got an alignment appointment to confirm the tracking and we are back in business.

 

Friday brought rain...messing up the chassis! Only water...so off to the alignment rack we go:


-2.5/-1.5 camber front/rear...easy, peasy. Clutch still impressing me at OEM driveability. So far quite happy with the challenges of install of the single disk ACT setup. Glad I have a good alignment man to depend on...not cheap, but with 13 GTRs in the parking lot - quality work.

Next to finish the idle tuning...

 

​Another trip to the Nurburgring...with the obligatory check on topspeed of the vehicle...8000 rpm hard rev limiter = 160 MPH. Definitely gave indications that it could easily go faster...hmmm...how high do these 4G63 engines rev to? (or in our situation how high do we trust a 13 year old's work...ha!)

Great fun!

 

The Ring video...not a stellar time, but some traffic and conditions were damp - never know what the next corner is going to be. Still searching for a my good lap in this car...hopefully the camera angle is better this time:


The stiffer springs up front certainly avoided bottoming out on the g-outs. Did feel a bit more like understeer which can be expected with 120's up front and 90's in the rear. Car still feels like it is a pogo stick on the lumpy surface - doesn't instill confidence, but maybe that is how it is.