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96 Tracker build - getting serious post 72+

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #90 on: December 04, 2010, 11:38:15 AM »
I think 200 HP is a good but conservative figure, but if I were building your engine, I would use the 16V crank, it has double counter weights and is supposed to be better at high RPM by not flexing the crank like a single counter weight can do

Wild

A little relieving that the 16v is less prone to the warp issues as that's what I have.

I just ordered a CXRacing front mount (18"x12"x3") off ebay, hoping to be able to tuck it behind the grill infront of the radiator after I remove the condenser.

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #91 on: December 08, 2010, 05:46:27 AM »
FMIC will be here in a few days. Have a piece of 3.5"x3.5" .120 wall box tubing I'm going to make a custom upper for my intake mani to relocate the TB to the front. Black item in the picture is a 6 port vac block so I don't have to drill/tap so many holes in the plenum.

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #92 on: December 15, 2010, 07:36:24 AM »
 :( Just stopped shaking... the machine shop called and gave me a price for ALL the work I want/need done. I gave the green light anyhow. This is going to be frikking sweet! I can't wait till everything's done and a few hundred miles after 1st startup to beat on it!!! Now... since I'm spending so much on the engine, I have to go legit with tuning.

Driving down Friday to put ~50% down and get paperwork to show what's being done!!! The 1 rod bearing that spun is getting welded and remachined to OE Honda specs to match the others. I'll put up a full list of what's getting done probably Saturday.
« Last Edit: December 15, 2010, 07:38:00 AM by yellow2000S/R »

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #93 on: December 24, 2010, 08:03:19 PM »
5 new holes drilled and 1 slotted and it fits! Flange is slightly warped so I'm probably going to get a quote to get it milled at the shop. What can you expect for a $100 ebay manifold?


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Offline wildgoody

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Re: 96 Tracker build - getting serious post 72+
« Reply #94 on: December 24, 2010, 08:52:37 PM »
So what was that manifold built for? a Honda or was it custom for the 16V Suzuki
Real Trucks Are Built, Not Bought,
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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #95 on: December 24, 2010, 10:00:36 PM »
So what was that manifold built for? a Honda or was it custom for the 16V Suzuki


Below is a link to the manifold I purchased. It is for a 'Mazda Protege 5 1.6l' t3 setup. The flange that is already on the manifold is large enough that I just drilled 5 new holes and slotted 1. The front most hole I'm going to use a small spacer with a washer to 'clamp' it to the head. For the rear most 2 bolt holes nearest the EGR passage I'm going to make a small plate to bolt on with a passage for the EGR setup then run a tube from that to the external wastegate port on the manifold. If I have some spare time tomorrow I'll drill out a few of the holes and do a quick mock up and post it in here. I already purchased a t3-t25 adapter.

http://cgi.ebay.com/ebaymotors/MAZDA-PROTEGE-5-1-6L-STAINLESS-STEEL-T3-TURBO-MANIFOLD-/250745531263?pt=Motors_Car_Truck_Parts_Accessories&fits=Model%3AProtege&hash=item3a61992b7f


t25-t3 adapter I just purchased. Going to drill out the threads for the t25 side since the Saab turbo is studded.
http://cgi.ebay.com/ebaymotors/GODSPEED-T3-T25-TURBINE-FLANGE-CONVERTER-ADAPTER-GASKET-/150536952497?pt=Motors_Car_Truck_Parts_Accessories&hash=item230cb39ab1

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #96 on: December 25, 2010, 08:20:00 PM »
Started on the custom plenum. Making it from 3.5"x3.5" .120 wall box tubing. Pied out a 1.5"x7" section and folded the top down, welded, and ground smooth. All holes for the mouting are drilled and tapped. Need to get shorter bolts. Tacked on a cap for the backside for now till I figure out what I'm doing for the vac lines and some sensor mounts.

Figured it'd be an efective way to shorten the runners and gain a larger plenum all at once, let alone relocating the throttle body to the end instead of side so it no longer goes over the exhaust area.




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Offline BRD HNTR

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Re: 96 Tracker build - getting serious post 72+
« Reply #97 on: December 27, 2010, 08:25:12 AM »
Great detail on this build.  Getting all the numbers together and deciphering them must have taken a lot of time.  Looking forward to the rest of it.
93 Tracker,XL7 springs & 1" raised spring pads in front with YJ springs in back, home built bumpers rear & front (w/winch), 2" x 4" rock tubes,  ARB front & rear, converted Sami rear to IFS, 33x12.5x15  aluminum rims, roll cage, 2.7L w/5 speed auto.

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #98 on: December 27, 2010, 09:57:51 AM »
Great detail on this build.  Getting all the numbers together and deciphering them must have taken a lot of time.  Looking forward to the rest of it.

At work (Amazon.com), workflow has greatly dropped off this week. Had off yesterday and today so the build is going to be slowed down. IF I loose my job the build will be put on hold.

In other news, the coolant outlet above the thermostat is in the way for the TB. I'm unsure if the throttle cable will even reach the TB being located way up front like this. I think the kick-down? cable will reach tho. Thinking about plating off the end of the plenum and running a 1.5" length of 2.5" tubing to yet another flange that I can then bolt the throttle body to. Waiting till I get the engine back so I can drop the block in and set the head on and see if I should continue with the plenum build or not.

Anybody know of a place that makes custom throttle cables to get one longer?

Re: 96 Tracker build - getting serious post 72+
« Reply #99 on: December 27, 2010, 10:17:57 AM »
Way late on asking this, but, back on page 2, you say that you are going to be moding the LCA for camber adjustment. Is the 1.5' x .75" ball joint RE-location mod, or are you doing something different?

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Offline yellow2000S/R

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Re: 96 Tracker build - getting serious post 72+
« Reply #100 on: December 27, 2010, 10:54:10 AM »
Way late on asking this, but, back on page 2, you say that you are going to be moding the LCA for camber adjustment. Is the 1.5' x .75" ball joint RE-location mod, or are you doing something different?

I cut the control arms and moved the joint forward and outward at the same time. I forget the measurements of what I ended up doing tho.

Re: 96 Tracker build - getting serious post 72+
« Reply #101 on: December 27, 2010, 11:18:03 AM »
 Ok. That's what I was wondeering. Thanks.  For your throttle cable, have you tried outfits such as Lokar? They offer DIY kits for all kinds of things. High quality, too. Like showcar grade stuff.

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Offline bentparts

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Re: 96 Tracker build - getting serious post 72+
« Reply #102 on: December 28, 2010, 05:09:48 AM »
Nice buildup so far. I was taking a good look at that turbo manifold you got off ebay and I have to tell you I'd be concerned with the thickness ( or lack therof ) of the tubing used to build it. It looks like plain old stainless exhaust tubing, and from experience I can tell you it won't last long. That thin wall stuff is prone to burn through, cracking and coming apart at the weld areas. While you have it off you might want to brace it against vibration, and to support the weight of the turbo better. jmo.
Also do you have any pics of your control arm mods?
The usual stuff, and 2nd generation Air to liquid intercooled TURBOCHARGER

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Offline wildgoody

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Re: 96 Tracker build - getting serious post 72+
« Reply #103 on: December 28, 2010, 08:58:06 AM »
Hey Bent, you think even in stainless it would burn through?

I was looking at lots of different manifolds that are available, just
to see if there were something that could be easily modified to
be custom fitted to a 16V Suzuki engine, and that fits the right
location in the engine bay for ease of install.

I found one that I think will work well, and even contacted a
company to see if they will copy a prototype. Many if the specs
say the tubing is 2.3mm thick, which sounds thin but that's about
1/8" and should be fine as long as you support the turbo or brace
the manifold properly to prevent cracking

Wild
Real Trucks Are Built, Not Bought,
And Chrome Don't Get Ya Home.  

An armed man is a citizen. An unarmed man is a subject.

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Offline bentparts

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Re: 96 Tracker build - getting serious post 72+
« Reply #104 on: December 28, 2010, 10:01:33 AM »
Depends on where it's made from what I've been told by the local trubo guru's. Many of those Chinese made manifolds use an inferior stainless, it will actually begin corroding soon after install. They are also know for cracking after just a few hours of run time. I'm sure there's probably good ones out there, but all the ones I've seen that were built to be durable were made out of pretty heavy wall tubing, making the manifold itself pretty heavy. I've looked at and held a bunch of quality built turbo manifolds and most of them were as heavy if not heavier than a stock manifold, the cheap Chinese made ones were quite light, much like the first one I built. It lasted less than 6 months, and that was with several repairs. That's when I finally built a good one out of heavy wall stainless. Schedule 40 grade 304.
I imagine you could add some bracing to support the turbo and help with vibration damping, but the thinness of the tubing walls will do more than just deteriorate and crack, it doesn't hold in the heat very well, and the heat is what really runs the turbine side. It also requires much more heat sheilding due to heat leakage and heat soak.
But hey, if your just building a toy, no big deal. Just be prepared to be under the hood regularly for repairs. Just sayin'.
The usual stuff, and 2nd generation Air to liquid intercooled TURBOCHARGER