fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

ok, so rebel inspired me to put a few pics up here for the masses to see my trusty ute and all its mods :-)

heres a copy paste of whats been done :

piecemeal stock long block including :
fe5a camshafts
ground to fit vr6 valve springs
intake retainers/collets on all valves
f2t windage tray cut to fit...
...fe-dohc main bearing braces which have been ground to fit the above
custom winged sump with top plate to prevent slosh in the very most effective way
large oil cooler std on fe5a version
pistons are 10:1 variety

external to the long block are :
custom thin walled equal length mild steel exhaust manifold made with mandrel bends a mig and a couple of laser cut flanges, it incorporates an external 44mm vband wastegate and t3 fitting for ease of downsizing in future if i should so choose, a hand made merge collector filed to perfection on the inside that brings the flow together so well that with the 44mm wastegate wide open a great deal i had 3.5psi by 7k rpm.
one holset he351cw hy35 hy9 turbo from a 2006 dodge ram cummins powered diesel pickup truck modified with custom made matching vband flange for dump pipe, removed wastegate actuator, welded up wastegate hole with a steel plug shaped to the inside of the turbine housing for smoothness of flow welded in place and the bracket for the actuator cut off and ground smooth to just fit the engine bay at all, a modified cummins drain pipe that snakes around the compressor housing and engine mount and back to the sump at the full 22mm OD size. dumping to...
one full straight through, and you know i mean straight, custom 3" exhaust with the biggest coby reso/tube muff at 18" and a cheapish oval muffler dumping just in front of the diff, initially fed by a 4"to 3" fred welded reducer and smoothly merged in wastegate reentry and ...
innovate wideband O2 letting me know that its dead rich.
one chinese 44mm vband wastegate with 15psi spring and welded valve lapped to a perfect seal.
one "bagel" inlet manifold and plenum to smoothly guide the intake gasses to their firey death with short runners smoothed on the inside and tuned for high rpm power and flow, large plenum volume with throttle directed to allow air to enter all cylinders quite evenly
one modified stock fuel rail bored an extra .3mm with blanked stock input and retained fuel pressure dampner and 3/8 inlet fitting and 5/16 outlet to the fpr and...
4 rx7 550cc injectors cleaned by some brakeclean and a heater with new orings and spacers and seals
one chinese adjustable fuel pressure regulator and guage returning to tank along the stock tube offset slightly and passing to...
the stock feed line that used to supply the carbed engine at 5/16
one brand new 3/8 feed line all the way from the fuel system at the rear
one 70mm lexus 1uzfe 4.0l 280ps v8 throttlebody modifed to have no second throttle plate and no air leaks etc and fed by....
one r32 nissan skyline gtr intercooler with 3" inlet and outlet and 3" plumbing with silicone couplers and tbolt clamps and enough flow for more than 500hp mounted fwd of the radiator with short pipes and good airflow over it, cleaned to bare ally by many washings with thinners etc, and with all fins straightened on both front and back to maximise air flow through it
one nissan gtr r32 bov housing and two stock bovs from same car attached in the wrong place immediately after the turbo instead of before the throttle with socks and cable ties for air cleaners blowing straight back up into the air filter which is a....
6" inlet dual cone simota unit (one of the biggest they make) attached by a shortened and lightened and internally sanded pcv feed pipe in 4" ID all the way to the inducer of the turbo
a hard oil line with banjo fitting on the turbo and rotating type on the block, with no restrictor and about 1/4" OD line brazed at the ends
a customised crank pulley with siera cvh 36-1 wheel grafted on and a nice paint job to make timing light mark id easy
a customised f2t flywheel machined down to accept the stock ring gear and go inside the small bellhousing and fitted with a modifed and balanced 1X00 pound pressure plate also machined down to squeeze into that bell with a heavy duty sprung organic LUK clutch disk inside
custom coolant lines in 35mm OD steel tube with mandrel bends and quality hose
bp 2 stage thermostat residing inside f2 flat thermo housing at the back of the head as it should be
53mm thick R33 jap made full alloy race radiator and two american curved blade fans on the front all supported by...
early 90s top mounts from galants, and lowre mounts from same period legacy (same for intercooler)
four short bosch ign leads and fours stock fe3 coils and four stock fe3 ignitors controlled by...
one modified ms2 v3 unit with provision for leds on all main outputs and COP capability with external switch for bootloading code
semi decent wiring setup including dedicated feed to ms from battery, shields on all inputs, dedicated feed to battery from alternator, extra heavy grounds (50mmsq) to block from battery, and same to starter and all other feeds from battery, vref line to alternator from battery itself, heavy ground to ms from head, dirty power feed line from main car system for such things as 02 heater feed etc.
at the rear of the vehicle
two bosch fuel pumps, one circa 400hp 910 sucking fuel from tank through a big marine filter/water seperator, and feeding a 2l s/s surge tank with 3/8 line, returning excess to the main tank through a 1/4 line to create some residual pressure, and one mother of all bosch pumps 044 sucking from that surge tank and pushing upto 800hp of fuel fwd through the 3/8 line mentioned earlier.
battery relocated to behind the diff for weight issues and very short thick wires straight to those pumps from it. all wires from batt either fused or broken for safety and convenience.

will add some pics if there is any interest :-)

cheers,

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

More pictures, less words. :X

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

Pictures please, sounds neat.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

my customised megasquirt with 4cyl coil on plug and a few other little tricks
Attachment 25998
the back of it with the fuel/batt box clearly visible behind the hinged number plate
Attachment 25999
front view nearly ready to go with my mate mops standing working on something
Attachment 26000
four stock fe3 coils, four stock fe3 ignitors, chinese fpr, modified fuel rail, 550cc rx7 injectors (maxxed out for approx 385bench crank hp)
Attachment 26001
rivetted intercooler plumbing with a pair of nissan skyline gtr blow off valves in a stock housing with 50mm inlet and twin 38mm outlets
Attachment 26002
intake side of the engine bay
Attachment 26003
custom plenum with 1uzfe 70mm throttle body from the lexus/toyota 4l 280hp v8
Attachment 26004
one of the biggest simota air filters you can get with 6" to 4" toilet plumbing to the turbo
Attachment 26005
the inside of that plenum showing the totally smooth path that the air has to flow through to get into the engine
Attachment 26006
where 3" end of downpipe meets 3" exhaust
Attachment 26007
exhaust side from above with manifold, turbo, wastegate, downpipe and coolant plumbing all visible
Attachment 26008
and from its prettiest angle
Attachment 26009
hand crafted 4" to 3" downpipe with hand turned on lathe vband flange for turbo and flexi for the wastegate
Attachment 26010
Attachment 26011
the nearly perfectly straight 3" exhaust with two straight through mufflers, also showing the 130 s/s m8 csk screws holding down the 17mm plywood deck
Attachment 26012
where the battery lives with 4 fused 5ag outlets and one 100ampere circuit breaker with 50mmsq cable going to block and starter and 8ga going to ms and another to alternator and a speperate vref to alternator and a sperate fuse for lighting and the last one for the pumps. also 2 8ga local grounds to the ally panels.
Attachment 26013
the rear ally panel from inside showing the two relays for the two fuel pumps, the brake,tail,reverse light relays, and the ground lift all rear lights off the cops are coming relay
Attachment 26014
044 910 raycar and surge tank. all happy to supply 400+hp of fuel, and peak of about 700-800 through the 3/8 line straight from the 044 to the rail.
Attachment 26015
ex mani on the Persian rug in the lounge just after completion.
Attachment 26016
just after painting
Attachment 26017
holset just fits, mounted with begginings of beautiful hand made merger above.
Attachment 26018
36-1 crank trigger with bracket and sensor
Attachment 26019
winged lidded sump for zero oil surge under extreme driving (i'm crazy incase you are wondering and pull a G daily everywhere)
Attachment 26020
f2t flywheel with fe smaller ring gear and ligtened and smoothed and shrunk to fit the 240mm clutch in the small 225mm bell housing.
Attachment 26021
about to go in. you can see the coolant plumbing. the periscope one got changed twice after that. type 3/r box visible in background
Attachment 26022
2 pack laquer paint job on diff housing looking sweet on a warm summers day.
Attachment 26023

that will have to do for now,

well, except the vids, if you wanna see em. nothing too flash, just a few donuts and a bit of windy road...

let me know.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

very neat!!!

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

Attachment 25992

This picture makes my scalp itch.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

great fab work fred and a great project so far! im looking forward to see some dyno plots and track runs :y

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

I love that intake. I love it all, but yeah, that intake is cool. What's it made of?

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

That is awesome.

:6

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

front page!

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

f'n A mazda goodness! i go away for two months and come back to mazdamadness in this join. sweet jesus!


NEUMAN

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

http://www.germes-online.com/direct/...ary_Napkin.jpg

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

i just found my new role model... you are like a mad ------ scientist... awesome! :y :y :y

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

Thanks everyone :-)

the full detailed buildup thread is on mx6.com here for now :

http://www.mx6.com/forums/fe-dohc/18...post-here.html

its a LOT of reading... and a LOT of pics, but if you are keen readers...

danman, i strongly LOLed about that post :-)

nice work.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

the intake is mild steel. i only have a mig... will buy a tig inside the next 3 years.

here are the vids :

some fastish driving, note rhd, lhs of the road country :-p and its wet and its windy, but i still got over 90mph out of it in a few places. in my skyline which is NA i only hit 100mph twice on that road using race tyres in the dry, so getting there with a throttle sticking open, only front brakes, wet road etc is quite good really.

http://www.youtube.com/watch?v=jxDAjVh47Ao

and after that, did these donuts :

http://www.youtube.com/watch?v=BLP9Pjno6kw

enjoy.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

I didnt know most of the stuff i was looking at, but it was all nice looking! :S

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

what dont you understand? i'd be happy to explain :-)

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

It looks really good, but you need some cliff notes.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

thats sickness

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

bump for the cliff notes whatever they are added above each picture. thanks again.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

thats badass. i love the oddball stuff

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

can you enlighten me on the benefits of the dual bov?

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

more air can get out, less chance of surge. probobly overkill but if you have two of them why not?

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

thanks phil :-)

packaging and flow i guess, it was about 65 nz dollars (35us?) shipped, with the housing, its capable of about 700hp or so. the only thing on the car not capable of 500hp + is the long block :-) but i'm gunna test that bastard to the max when i get back. 25psi with 50% toluene and we will see what it can make. i reckon 450whp isnt out of reach. we will see. its off the exact same car as the intercooler, it makes 280ps stock, and is tunable to 450 on stock turbos easy.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

holly mother balls!!! :o

that is some amazing fabrication and craftmanship!!!

major props dude

-Luke

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

Thanks mate. I learned to drive in that thing a decade or more ago. I've been a lot of places and had a lot of good times in it, so when it failed its wof on rust, i had to do something, and being a bit of a perfectionist, it spiraled out of control, esp when i got some decent income a year ago. i basically did that in a period of only 5 months working solidly many hours a day everyday.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

Awsome.
Front page!

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

Cool, what are the tires on the rear?


JP

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

embarrassingly two different ones. i sent my mate to get them swapped off of my skyline rims and said make sure there is a left and a right of each, and he comes back with two Dunlop DO1J lefts and two Toyo R888 rights. interestingly they seemed to be pretty well matched for grip, though their was a bit of pulling under brakes from slightly different diameters. I wouldnt buy the dunlop again as the toyo is as good and 2/3 the price. tested to 1.1 G on the nissan. yet to be gtech logged on the ute.

the size is 225/50R15 and the wheels are terrano/pathfinder chromies that weigh a metric tonne each. there is a lot left to do to her before i can lap all wrxs and evos at the track (windy one, not 400m long) but at the moment it would beat most on a 1hr tune, and untuned setup. its pretty quick.

1st gear is gone in a blink, you shift as the boost hits and wheels let go, 2nd same sort of deal, though if lucky the grip will outlast the boost in 2nd, then in the dry its good to 100mph in 4th. didnt get a clean dry run on the motorway with boost unfortunately, so cant really say, but it will revlimit at 7500 in 5th at 210kph or 125mph, and i know it will get there so so so quickly...

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

believe it or not, i dont have a decent from picture...well, not that i've found looking through the 1.5gig that i have of it. but i did swipe this from a video clip that i didnt post because of the plate...

Attachment 25882

if i find a better front view, i'll whack it up.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

placeholder for something i guess. not sure just what yet...(accidental post)

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

guys a fag

no pics

no porn

/yourself

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

i'll be stuffed if i'll be left banned with my intellectual property locked public in perpetuity. if its just a bunch of losers talking tough, then maybe it will reappear, and if not, then i lose nothing. /yourself lol, your more geek than me and do software for a living...

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

geek? far from it my friend. i dont think theres anything "geeky" about welding. but far be it from me to question your uncontrollable knowledgeabilities, and perpetious public property.

you talk like a fag, you look like a fag....maybe....you are a fag

this is the HMT way, noobie

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

typing /yourself as a way of saying finish yourself or kill yourself is the height of geek :-) whether you weld or not.

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

go ---- a kangaroo, you aussi inbred

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

really good at geography too. top class mr america :-) your neck is probably red from snow burn...

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

i am a redneck and proud of it

no geek, just redneck

man, i cant wait for tomorrow

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

have your say here :

https://www.homemadeturbo.com/forum/...?topic=81497.0

fred.

Re: fe3 / fe dohc + holset + ford courier (b2000) = good fun ;-)
 

AMERICA... ---- YEAH... YOU KIWI FAGGOT....

Austrailian??? You wish.