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Smudge's supercharged V8 build

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Has to be! Otherwise it's getting thrown off a cliff
Not commented on this thread yet, but I completely empathise with how these hard knocks can set your opinion of human beings backwards. Glad that the kindness of others have kept you going. Wish you better fortune in getting the car working how you want.

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First chance I've had to play about with the car in a LONG time! 

Cleared all the bits out (mainly broken parts) and removed some unnecessary parts like the rear speakers, rear seatbelts and 3rd brake light. 

Refitted my rear arch liners that have been sitting in the garage for a couple of years. 

Also unpackaged my new final drive of 3.58 ready for the diff rebuild. 

Couple of weeks before she goes back to Carson Performance for the engine transplant, need to gather a few more bits before then. 

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4 hours ago, slickrick said:

Ive never seen a halfords tool kit either complete or with the two sides still intact lol

Yeah mine fell apart years ago now 😂 need to invest in a proper chest but haven't got the room to put it anywhere 

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Lack of progress recently whilst I build up the collection of parts needs to give this 3rd engine an overhaul. 

I've decided to spend a bit of money on new seals, gaskets, pulleys, belts, pumps, bearings and bolts to make sure that this engine has the best chance possible. 

Currently researching who's best to rebuild the bottom end using ACL race bearings and ARP rod bolts, but sticking with the OEM rods and pistons as its not worthing spending £2k to upgrade those for my setup. 

The heads will be getting new valve springs, along with a port and skim to allow for thicker head gaskets and better air flow. 

This process will take a few months yet, but at least the collection of parts looks pretty! 

Also had my Bullet intercooler turn up which sandwiches between the supercharger and the inlet manifold, to help those pesky high inlet temps! Lovely engineered bit of kit. 

In the meantime, I've been stripping down the engine to the bare block and heads. Over 30kg worth of wiring and acilliaries removed! 

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11 minutes ago, maurice said:

Is it really necessary to rebuild the 3rd engine? Seems like it would be safer to leave it unopened.

Not necessary, but worthwhile for peace of mind that everything has been checked and replaced where possible. 

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How come you can't run a front mount intercooler? Wouldn't that give more stable intake temperatures? 

If you're getting the engine rebuild with reinforced internals but not forged rods then are you considering new oem rods just incase the factory ones have any stress from the donor car use. I'd just be very concerned of the engine failing from the weakest part especially as you're running boost. 

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5 minutes ago, Luke said:

How come you can't run a front mount intercooler? Wouldn't that give more stable intake temperatures? 

If you're getting the engine rebuild with reinforced internals but not forged rods then are you considering new oem rods just incase the factory ones have any stress from the donor car use. I'd just be very concerned of the engine failing from the weakest part especially as you're running boost. 

It's an air to water intercooler, so I'll also be getting a front mount which cools the water going through the cooler before the inlet manifold. 

The rods are THICK in this engine. The extra expense and time needed to install forged rods isn't worth it with OEM pistons. Plus you need to be north of 600bhp before you really have to consider forged components which I'll be well below. 

In an ideal world I'd forge everything, but budget doesn't allow for that I'm afraid. 

We're doing the best work on a realistic budget to make this engine more bulletproof than when it came from the factory. The ARP rod bolts and ACL bearings will be the biggest upgrade in terms of reliability. 

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Last few days have been spent stripping down the engine completely, ready for inspection, measuring and ensuring everything is good before doing anything major. Was good fun getting my hands dirty for the 1st time in a while, and good to see the ins and outs of the engine too. 

Rogue Motorsport measured all the bores, crank and pistons today. Happy to report that everything is as good as it can be, meaning I'll go ahead and get everything professionally cleaned and painted up before we start the build itself. 

Just waiting on the new oil pump to arrive and need to order some new OEM rings now we know the gap measurements are good. 

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Amongst more personal and financial issues for the last few months, I've been very quiet on the car front. Until NOW! 

Heads have been dropped off to a specialist place up in Rotherham to have an overhaul. Skimmed, new valves, uprated springs, porting/gas flowing and a general rebuild of all the internals. 

The 1UZ heads are known for being quite restrictive so this should free up a few more horsepower. 

Once I have those back, the engine will be given back to Rogue Motorsport to rebuild from the sump upwards. 

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Still lots happening behind the scenes, with the car going back to Carson Performance on Monday for a bit of prep work whilst the engine is being worked on elsewhere. 

The heads are still undergoing a porting and rebuild procedure, but unfortunately it's come to a stop whilst we wait on some new, stronger, bronze valve guides from New Zealand.

And I'm now anxiously waiting on parts from all over the globe! My most favourite being a very neat bit of kit called an interchiller, which essentially works the same as a Water-to-air intercooler for the supercharger, but the fluid is further cooled using the A/C system to get FREEZING inlet temps which of course means more power. 

Not a cheap bit of kit and looks quite fiddly to install, but very exciting nevertheless. 

Stay tuned for big updates over the next few weeks... 

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Couple of deliveries containing vital parts to the build have arrived this week. 

First off from the USA, we have a 7 gallon (American gallons, so around 23.5litres) water tank with an inbuilt pump, capable of pushing 2000litres of fluid every hour! This will be a vital part of my cooling setup for the supercharger to keep inlet temps as low as possible. 

Semi circle shaped to fit nicely into the spare wheel well of the 86.

Next up from Australia is a funky bit of kit called an interchiller. This is the same principal as a water to air intercooler, with the added benefit of tapping into the A/C system to chill the coolant to FREEZING temperatures. This ensures that the inlet temps should even reach ambient, giving us more consistent power on the track. 

This will sit on the sidelines for a few weeks until I get time to install them. Got to work out all the different size fittings and hoses I need next, as they're all different of course 🙄

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Been a while since I updated this, also cleared out a load of chat so hopefully people can post replies in here again.

All in all, very slow progress. Matt and the team at Rogue Motorsport have had my engine for a few months and been nothing short of amazing. But as usual, it's been 1 step forward, 2 steps back... 

Originally, the block we had came back from the machine shop with pitting inside 3 of the bores. So was deemed scrap as it sat below the 1st oil ring. Another block was sourced, but was no good on the tolerances when we measured it up against the pistons. 

So I decided to stop trying to piece parts together and get ANOTHER complete engine. My 4th V8 in total! It was sold to me as only having 44k miles on it, and after stripping it down, that seemed to be true as everything inside looked brand new. Matt got measuring again and the internals that we'd already had balanced up were perfect fitment, so the bottom end is all looking good for once. 

Unfortunately, the work I had done on the heads was below par. The seats and valves had a lot of rough edges and it seems that the new guides are also not fitting properly for some reason. Waiting for Matt to give me a full breakdown when he gets a chance to go back into the workshop sometime next week, as Rogue have closed down during this quarantine period as many other businesses have. 

I'm the meantime, I've been researching the best setup for the VLAND headlights as I think they give the front end a much nicer look over the OEM lights. Only issue being, they are compatible with the OEM xenon setup, which means I need to swap over the OEM ballast and xenon system into the new VLAND headlights. 

After much deliberation, I decided I don't want to be left with just a shell of an OEM headlight, so I've opted for a separate xenon system specially designed for the GT86 with VLAND headlights. Coming all the way from Canada, I'll do a full write up on the system next week when it arrives.

Test fitted the lights this morning to see how they look, and I'm very happy with the overall result and fitment! Gives the front end a more modern look with the black housing. 

 

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3 minutes ago, Luke said:

You must be missing driving it right now. I get withdrawal symptoms after a week away from mine. 

I haven't driven it properly in over 4 years, so I don't really miss it anymore 🤷‍♂️

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Installed the Intec roof mounted brake light the other day. Had this sitting around for about 2 years so figured I'd do something during lockdown. 

Gives much better rear visibility for both the driver put the rear window and those behind you when braking, as it's a much larger and brighter unit. 

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