Great SS-Four rebuild 2010-2011, Thanks Wolf... (VIDEO update April 22nd) Options

[malpaso]

What to say. The time has come to share in pictures with the great re-build . Works it self are not finished yet and exact due date is not known as well (since as always something unexpected can pop up anytime). Everything has started in August 2010 after my Alpine road trip (also some pics here). I really wanted to say to my car decent good bye (before I leave it thousand miles from home in Italy) for many months. As time and money comes and goes things has changed a bit from the beginning but that is not important. Important is that everything is on the best way it should be now. I will share more with pics than with words because I know everyone likes pictures more than reading ...

Primary target = rebuild the engine
In fact engine it self was not any bad. But it do not mean everything was mint with the car/engine (as can be seen in some pictures later).









Since my mechanic wolf_tm is super-precise person everything must be clean and perfect.





















Almost everything in the engine was replaced by performance parts or new OEM parts.





Of course also clutch was replaced by more durable one and flywheel was skimmed and balanced.





So engine done... almost (done means "closed" ). To be continued...

This post has been edited by malpaso: Apr 22, 2011 - 9:19 AM

[SwissFerdi]

That looks like an immensely precise rebuild. Awesome, just awesome. Best of luck my friend, can't wait for another ride when the engine's new and improved!

This post has been edited by SwissFerdi: Feb 20, 2011 - 10:50 AM

[Urputus]

Looks like you'll have completely new car So many new nice parts, Wolf's precise work in addition to it, what else to wish for?

[malpaso]

Ferdi, you remember when driving in Switzerland I was complaining driving up-hill I would need more power sometimes to enjoy ride better? So I decided to make it double this time to be sure . When we meet again you see how much difference it is

EDIT: Just read note above and realized it may look like I plan the engine with 500HP. To make things clear no I do not . It would be possible if I had more money now and more sense of reality two years ago . Anyway... true is as found by mechanic later my 3SGTE had around 160-200HP driving Stelvio. Not more.

Paul, no one else but you knows how hard it is for me... You hear my complains how I miss my car almost daily . Thanks for support!

Now... lets share bit more pic again...

Time for turbine
Sad is because of budget problems (and my stupidity in 2009) I needed to use turbine that has been bought for previous project. Now I would buy definitely some different but... Nothing is perfect. However as noticeable in one previous picture header skim was needed as well...



...and also small upgrade of the radiator.



Here turbine it self and installation.









This post has been edited by malpaso: Feb 21, 2011 - 4:31 AM

[Bigstring]

Cracking buddy, what have you paid out so far for this re-build?

[Sunny]

Hi Martin,

looks liker very good
when do you plan to pick your car up?

greetz

[makis]

Good job but with intake by caldina will be better great!

This post has been edited by makis: Feb 21, 2011 - 1:08 PM

[Ted95]

good job broo!

[malpaso]

Cracking buddy, what have you paid out so far for this re-build?

Honestly I'm afraid to calculate . But true is it would not be easy anyway because original plan was use as much as possible parts I have bought in 2009 for previous project. Unfortunately most of them were useless for my build and replaced... and some used (due to budget issues or just because they were fine to use). What should I do since I'm not millionaire... However exact amount I really can not calculate at all since first part bought two years ago, some of them sold and bought another... Really hard to say. I only know I'm dry with budget now .

Hi Martin,

looks liker very good
when do you plan to pick your car up?

greetz

Not easy to say Alex. Probably in next 4-6weeks but who knows... "to do list" is still too long for predictions.

Good job but with intake by caldina will be better great!

Technical details are fully in hands of my mechanic. His opinion is untouchable for me .

good job broo!

Thanks! Can not wait to see it...

Just few more pictures...

Engine management
First plan was to use Motec but because of budget reason (as usual) in the end I have bought APEXi ECU for ST205. So no wiring issues at all and easier tune up.



Also decided for wide-band sensor and A/F ratio gauge (so gauge no.5 since I already have boost, oil temp, oil pressure and EGT).... it will look like airplane cockpit . Custom pod is under construction by DCW now .



This post has been edited by malpaso: Feb 22, 2011 - 6:10 AM

[808celica]

Awesome work as always Martin I wish I had the patience and money as you do

[Sunny]

Hi,

i hope it is not between the middle of march until the first april week as i have a further education this time

let me know when you plan to visit me

greetz

[malpaso]

Awesome work as always Martin I wish I had the patience and money as you do

Thanks mate... fortunately this time I'm just moneybox and work is made by some who know damn good what to do and how . No experiments allowed this time

Hi,
i hope it is not between the middle of march until the first april week as i have a further education this time
let me know when you plan to visit me
greetz

Alex, that is the plan. I will definitely drive back to CZ through Austria so this is clear . What is not clear is time . There is really a lot of work to do as you will see from pics later...

[malpaso]

Secondary target = to get rid of the rust
During installation of stronger fuel pump issue with the rust has been found… From first sight it was not that bad but when fuel tank was removed everything was clear. That rust must go first. It is useless having perfect engine when can drop out from rusted body anytime. First run of new engine must be postponed until this is resolved . See pictures below what is the condition of under-body parts…

[3WayStunna]

Wow thats alot of rust. How do you plan on takling that? Wire wheeled tools, and some paint perhaps?

[malpaso]

Wow thats alot of rust. How do you plan on takling that? Wire wheeled tools, and some paint perhaps?

Yea... It makes me really desperate... there only way to replace what is in really bad condition, what is not that bad sandblast and cover with anti-rust paint. So far everything that can be removed from under-body is removed to find the right way what to do.



Also as you can see was not possible to remove an arm from the crossmember because the rust jamed the pin inside



This post has been edited by malpaso: Feb 25, 2011 - 3:58 AM

[BonzaiCelica]

oh my!!! Flawless work Malpaso, keep it up so far so good!

[gt4st205]

I really hope you can get that cleaned up without having to replace to much! Great work so far!

[Sunny]

Hi,

i would advise to powder coat the parts as it is stronger

greetz

[malpaso]

Hi,
i would advise to powder coat the parts as it is stronger
greetz

This is on my mechanic. He knows there is needed to remove rust and protect part from rust... also my problem is budget so also money talks.

I really hope you can get that cleaned up without having to replace to much! Great work so far!

Thanks a lot. I hope so... every more serious complication means delay and more costs .

oh my!!! Flawless work Malpaso, keep it up so far so good!

Thanks. At last the "to do list" is short enough that worth to try write it down .

- take rusted parts to sandblaster
- take them to painter
- install them back

(this will be in waves not all at once probably)... than after:

- install downpipe (with wideband O2 sensor this time)
- install turbo support
- make and install downpipe support
- make and install cold intake box
- install trans shaft, rear diff and supports
- install exhaust

and... at last switch the engine on and make running for 30 minutes.

- very first map check to avoid any detonation with stock PFC map
- check wiring and Datalogit logs (especially O2 sensor)
- check everything (leaks/levels/pressures etc...)
- had a little trip to control boost controller is working

That would be the moment I will travel to Italy and to follow with:

- 1000 kms running in
- change filters and oil
- Dyno tune
- recheck everything (leaks/levels/pressures etc...)

Get her home

This post has been edited by malpaso: Feb 27, 2011 - 1:19 PM

[FORGMANN]

Not sure you can get in Europe but get some POR 15 and do
all the susp etc in this stuff.. stuff is awesome and will not
come off and will not rust ever.. I am doing my st205 in this ..

Also it dries in gloss black so all the bits underneath look brand new

http://www.por15.com/POR-15-Rust-Preventiv...int/products/1/