I JET
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Everything posted by I JET
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Thanks mate, I enjoyed your build thread. Love them GT335 wheels. I think I'll be getting a set of those in the future. Yeah fab work is easy if you have the right tools. I wish I had access to a CNC and a laser cutter. I have a work friend who's father owns a machine shop. He designs and makes all his own parts for his old porsche race car....eg complete billet control arms, wheel hubs, billet rear sub frame, intake manifolds...I wish I had access to that shop. Id be there all weekend making cool sh!t for my car. that's funny mate. I mainly use Inventor for all my 3d work but due to some clients, I also use solidworks & of course good old autocad. I think around the christmas / new year period there will be a few games played.....I should show you all whats behind the back fence
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11. Few picks of the finished engine bay. Car is going in for its tune this coming Tuesday at CMS. Will update thread as it all happens.
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10. Airbox. Continued... Nutserts all in Foam seal for the lid just to finish it off and fill any gaps between the two pieces. Rubber seal for the intake, again just to finish it off and seal up the gaps. I was only able to get a small amount of the rubber seal. I was hoping to run some around the bottom of the sides as well. Will come back to this at a later stage after its tuned. Side and intake installed, this had to be installed as one. Lid on and stickered up. I'm pretty happy with the result. I still want to seal up the bottom a bit better so it is forced to draw more cold air from underneath the headlight. I will revisit this when I get some more of the rubber seal.
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^ I use to work as a mechanic. I got out of the trade about 6 years ago because the money is shocking. When I finished my apprenticeship I stayed on at tafe for a further 3 years and did a Diplomer in Mechanical Engineering while working as a mechanic. When I was in my 3rd year of that course I left the mechanical trade and began working as a Fitter doing mainly shut down work. Through that work I gained contacts and was offered a job at a local engineering firm as a Mechanical Designer.
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^ you know it........and beer
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10. Turbo side Airbox.... I bought a Nizpro 4" turbo side intake but it didn't come with an airbox so I decided to make my own. After researching other brands I noticed that none of the turbo side air box's really seal off to form an air box. They are more of a heat shield I guess. They do keep the pod filter out of site and tidy up the engine bay. (the Process West one probably works the best at being an airbox) Note: this is probably one of those things that you're better off just buying. I happen to have a sheet metal press and a lot of spare time so I took it on. The Nizpro intake & filter without an airbox Watching motoGP, making cardboard templates Test fit Side wall flat pattern cut out Lid flat pattern cut out Side all folded up Lid folded up Holes all drilled. Was planning to get it powder coated but im keen to get it all finished and installed before the long weekend. So I settled for metal primer and satin black pressure pack. Picked up a nutsert kit & some rubber & foam seal to finish off the airbox nicely That's all I had time for this afternoon. I'll get the airbox finished and installed first thing tomorrow.
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9. Swirl pot modification.......When I spoke to Joe about booking in the ute for a tune, we were discussing my mods and he mentioned I may be running too high a fuel pressure with the surge & 044 setup. I put a gauge on the car and sure enough he was right. So to fix this there is a small orifice in the swirl pot that the return fuel exits. This can be drilled out to help return flow and get the pressure back down. I went in from the top as to pull the tank out the bottom is a royal PITA on these utes, specially without a hoist.Hard lid off & tub liner outDrill out spot welds on left side of front panel to access fuel sender Fuel sender out Underside Removed this black piece The 2.6mm hole is the restriction Drilled out to 4mm All back together, checked pressure again at idle and its spot on now at 4 bar.
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The track is actually a very safe place to ride. Alot less obstacles. Wakefield is a great track, very technical and challenging, not much time to rest with that short main straight. I've been going there quite regular for the past few years. I try to go once a month when I'm not buckled from multiple fractures.
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Ok I cant seem to be able to edit my previous post's that I reserved so I will continue on from here. 7. Exhaust.....I picked up a turbo back exhaust on flebay for peanuts. I was after a single 3.5 but couldn't pass up a bargain. Its an xforce 4" dump into 3.5", twin 2.5" cat back all stainless. Decided to wrap the dump. I weighed up the pros and cons. Being stainless I didn't hesitate. The xforce system did not have a provision for the second o2 sensor after the cat. I'm not entirely sure if this will be utilized when it is tuned but I welded in a new bung so I'm covered either way. 8. Surge tank & Fuel Pump......Picked up an older style process west surge and 044 with a wiring harness. I replaced the elbow hose with a set of speed flow fittings. No check valve on the pump yet but I'm definitely going to add one.
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^yes...thanks mate. Going to swap it out for a dry cell today if I can pick one up.
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Cheers. Yeah I know what you guys are saying about the battery. There is pros and cons to having it there. My only concern is that it's not vented to the outside. I'm comfortable with the mount & location. I don't like some of the other locations and im not interested in putting it in the tray all though it may end up there.
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Reserved for Swirl Pot Modification Reserved for tuning, dyno, results.
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Reserved for Exhaust & Surge tank Reserved for Custom Airbox build
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6. Turbo....I was planing to just upgrade the turbo actuator to a 12psi unit. When I removed the stock actuator, I inspected the operation of the flapper and I found it was clashing on the housing wall due to excessive play in the bush. So off came the turbo. I decided to play it safe and get my spare stock housing modified. At lease this way I no I wont run into any problems. You can see the mark on the housing where it was touching. Turbo removed Swapping housings New modified housing fittedNew actuator fittedNew studs & nuts Installed back on car I'll Continue with the thread tommorrow guys its getting late. Hope the mods don't mind but I've reserved the next couple of post's so my build thread will be all togeather instead of spread over all the place. (only allowed certain number of pics per post)
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4. Handling........ On the front I went with Bilstiens & King Spring KFFL-57-520 + some new sway bar rubbers. On the rear I went with pedders heavy duty reverse eye leafs, Whiteline rear sway bar & new bushes throughout. 5. Intercooler....This was an easy choice. Process West stage 3 kit. Set and forget. I like the idea of the throttle body relocation and I was also keen to replace the factory hotside piping. PW is local so I went down and saw Kev and put my order in. Everything removed, waiting for new cooler The beast arrived After a little cutting, she's installed all plumbed up.
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Decided to do a build thread so I have all my mods documented in one place. BF2 - 2007 - #0166 - Lightning Strike Silver - Manual - 80,000km - Fully optioned - Est 350rwkw (getting tuned this week) I bought this ute in January 2013. I found it on carsales, it was up in North Sydney.The guy I bought it from was the original owner and still had all the original documents and receipts from Ford which was nice. I did see a total figure of $67,000 when he bought it new. Geeez. lot of money for a ute. I payed 22k for it. It was in really good condition cosmetically. 64,000km on the clock. Completely bone stock. Exactly what I wanted. The only issue it had was the hard lid didn't really fit properly which I came to learn was a problem with the factory lids. I ended up fixing it thought --> http://www.fordxr6turbo.com/forum/topic/89197-babf-factory-hardlid-fitment-issues-my-solution/ The turbo gave up the ghost after a few months of abuse but this was due to lack of maintenance by the previous owner and the standard oil feed line blocking. I replaced the core, installed an earls feed line with filter & also changed the exhaust housing while it was out to a modified one (ported, wastegate flap) I've been collecting mods over the past year or so. As tempting as it was to go get some injectors, a cat and a tune, I patiently waited as I decided early on the power figure I ultimately wanted, do it right the first time. I had a bad bike accident a few months back so while I'm not able to ride, I decided to just buy the remaining mods I need and get the car going like I always wanted. 1. I did my own battery relocation early on in the piece in preparation for a turbo side intake. Was pretty cheap to do. I mounted a battery box to the floor behind the drivers seat. Ran the +positive cable under the right side trim/scuff guards and up through the firewall where the clutch master is. This was an easy mod. 2. Decided to get a HID conversion kit. Just a cheap flebay one but it does the job and came with 2 years warranty. Not a bad kit considering the price. My last car had zenons, they are leaps and bounds ahead of the standard H4's Right side ballast & controller. Mounted to the battery tray. May as well use it for something. Left side ballast. Standard airbox wont be going back in. They are hectic bright. Need to point them down slightly (ask pixy angel) 3. Brakes. Still rocking the original rotors and the fronts are pretty farked. Replaced with a set of DBA T3 Clubspec slotted rotors. Brembo Pads had been replaced by the previous owner just before I bought the car so I resurfaced them and re installed.
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^ yep it hurt. Had a punctured lung from the broken ribs so I was on the side of the road getting treated for 3 hours before they air lifted me to liverpool hospital. No pacemaker there mate, probably just the wires from all the monitors I was hooked up to. Was in hospital for just over 2 months. This happened back in June. I'm still doing 2 - 3 hours of physio per day to get everything working again.
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^long time.... After coming off the the pca pain button after the first week I was put on 20mg of slow release oxicodone twice daily & 10mm fast release oxycodone every 4 hours. At first it wasn't enough and I was still in considerable pain but once it built up in my system it was pretty good. Specially the 10mg hit of endone. I had to ween off all that and now just taking 5mg of endone before physio and I have paracetamol throughout the day. All the result of going from 70km/hr to 0 in the space 0 meters. I wrote off the WK statesman that I hit. Note: A stationary vehicle on the side of the road with no indicators on can also mean he's about to make a right hand turn into a driveway on the opposite side of the road...couln't have timed it better if he was trying to hit me.
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^I know someone personaly who had a back injury but then tstruggled with endone for a long time afterwoods. I have to hide all my pain meds out of sight when he visits.
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here's my script and here, left knee and here, left wrist, hand & finger and here, right wrist. 3 Ribs top right of pic Ribs & multiple fractures to shoulder same side
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http://www.fordxr6turbo.com/forum/topic/65703-how-many-babf-f6s-were-built/
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You're getting closer Angel. I had to postpone my tune until next tuesday. Fuel pressure too high. Pulling fuel sender out tomorrow to remove the restriction in the return. Wishing I had a sedan. Giving myself an extra few days so I don't have to rush to finish things off. Started to make an airbox today for the turbo side intake.
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^bamk2f6tornado You should make good power with that setup, especially on e85. Still no e85 in my area so I'll stick to 98 for now. Also I'm still on stock valve springs so I don't want to the tune over 15psi.
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Still on the stock tune with stock injectors at the moment. It's running good but I have been keeping off boost. Even staying off boost it already feels much better. It's spooling up quicker and feels more responsive. The rear sway bar feels good but again without being able to put my foot down I have yet to be able to feel all the benefits. The stock ute handling was pretty bad I thought. Very sloppy and boaty. It's handles like it's on rails now. Sits flat, no body roll, hugs the corners, it rides firm but not harsh. The Bilsteins are definitely worth the coin. The rear sway bar will give it more predictable handelling. It should sit flat until you reach the limit of grip than start to oversteer, instead of understeer - body roll Than Oversteer.
