Peppy's Build Thread

["Captain Retard"]

Yeah I was assuming you had the manifold tapering into the enlarged port.

Maybe you could find a couple of larger inlet valves to pop into you experimental head and test the flow for future reference.

I've played with NA ports a bit , but never on a boosted engine. I suppose all things being equal, boosted and NA flow should like the same thing.

What your doing is fantastic for anybody going down this path in the future!

The more info and pics the better.

Well done for sharing this info!

Cheers!

[Peppy_t92]

The only oversize valves I know of are Supertech and it comes as a complete kit only, with 1mm over intake and exhaust valves, 90lb seat pressure springs, titanium locks and retainers, which they don't split up... Plus it makes it hard not having machines readily available to bore and cut the seats etc, so it's not a 2minute job.. I'm happy to stick with this at the moment, and do up another head when I build my de-stroked 1000+hp motor haha (2weeks)

Yea it's pretty much same same, the plenum is filled with boost then rushes into the necessary port, rather then trying to harness the pressure waves as in an NA.. only thing is you should pay more attention to the exhaust side obviously to get all that extra gas out!...

Thanks mate, I'm trying... Dad is the mastermind behind it I'm just trying to keep up and document as much as I can, he never had much to do with these motors so it's a big learning curve for him also, but it still gives an inside look at how a machine shop or proper performance shop will look at it because we're not your exactly typical backyard mechanics haha...

In saying that, this is just my take on it, it's not meant to be a "how to guide" haha, happy to give back to the community where I can

[barnz]

Yeah I was assuming you had the manifold tapering into the enlarged port.

Maybe you could find a couple of larger inlet valves to pop into you experimental head and test the flow for future reference.

I've played with NA ports a bit , but never on a boosted engine. I suppose all things being equal, boosted and NA flow should like the same thing.

What your doing is fantastic for anybody going down this path in the future!

The more info and pics the better.

Well done for sharing this info!

Cheers!

From what I have read turbulence is quite important on boosted engines rather than outright smooth flow, it ensures an even air fuel mixture hence the revised "swirl" chamber design on the fg heads. Like peppy said, exhaust side go your hardest. Edited 31/03/15 11:13 PM by barnz

[Peppy_t92]

Hey Guys, to say I've been busy is an understatement haha, unfortunately getting abit carried away so not to many pictures to share, but basically the porting side of the head is finished and I took it to a friend of ours to have it milled and the seats cut..

The block, crank, rods, pistons, balancer and flexplate are back at the other machine shop for balancing, and I have decide to go for the Fire Ring setup on the Deck, so I'm excited to get that back, hopefully this week..

Once everything is back I'll be sending the Pistons, head and valves to get ceramic coated... I'll be getting the crowns of the Pistons done as well as the chamber, valves and exhaust ports.. My std exhaust manifold and rear turbo housing are already done and I will be getting the dump pipe done once everything's back together as I need to weld an extra bung on it for my 02 sensor for tuning purposes..

We're 95% done on the intake manifold with extremely exciting results, it's actually flowing about 24% better then it initially did, with each runner flowing within 1% and is flowing better then the head, so it's good to see all our hard work paying off... It's actually at a stage where the top half of the manifold has no effect on the bottom half, so from the top half being the biggest restriction, to having zero restriction... So dad was right yet again and it's a bonus that it still looks standard and I don't have to change any piping..

Std (Google, coz I forgot to take a shot)

Most std picture I took

the bulk of it has been done, there's just some cleaning up to do then it will be all good.. We've looked at everything all the way up to the boost pipes and it all seems alright, there's some spots to clean up on the TB relocation but other then that we have to draw the line somewhere haha...

I also quickly cleaned up the bell mouth of the Niz dump as I wasn't overly happy with it

If you've followed from the beginning you'll know that I am running the KPM twin Intank system which I put my own Walbro 460 pumps in before it was released by Dave, it's obviously overkill but I'm running with it... I always had high fuel pressure issues so I got a Holley -10 reg, and some Teflon -8 feed and return, so now the smallest spot in the system is inside the fuel module... I'm quite happy with how it all turned out and it was quite easy to fit, so the fuel system should now be well up to the task, I will be lowering the base fuel pressure and doing some tests to see where it likes it with the KPM1500cc injectors

Once the motor is in I'll finish off the rest and I have some heat shield that should also help with keeping the fuel cool, which is overlooked by many people

and I got two -12 fittings welded onto the rocker cover, I'll work out a breather tank once everything's back together

Ohh and I've decided to take the plunge and to the box myself... Been doing a lot of research and have come to a conclusion of the main parts that I'll be using and have the repair manual and some forum posts as a guide, so I'll keep use updated as that comes apart and goes together

Thanks for reading Joe

[Peppy_t92]

I also got some Technico racing engine mounts and their ZF/Tailshaft coupling... Look like real good bits of gear and he's a top bloke to deal with

["Captain Retard"]

Not much left of the intake manifold

How many hours do you reckon you spent on it?

I would love to see a detailed ZF rebuild just out of curiosity and maybe future reference.

Once again thanks for the great pics and detailed write up

This is one of my favourite threads

[k31th]

Most std picture I took

LOLLLLLLLLLLLLLLLLLLLLL yep, there's definitely not much of that intake manifold left

Those are some lovely looking (sized) fuel lines 1500cc injectors won't be able to keep up with that much fuel flow haha

I also got some Technico racing engine mounts and their ZF/Tailshaft coupling... Look like real good bits of gear and he's a top bloke to deal with

Going to solid mount the diff, too? may as well increase NVH to the max with having both of these items

[Peppy_t92]

Hahaa your not wrong, it sounds real tinny if you knock it now haha, but all the spots that I touched were solid and have tried not to touch any of the actual walls... Hahaa if you were paying for labour it would probably be cheaper to buy a plaz or PW top half.. But if I were to do it again without stopping and testing every change it would probably take a good 6-8hrs (manifold), I obviously cut as much as I could with my reciprocating saw, then used the die grinder from there.. If I were to do the head again it would probably be around the 10hr mark including polishing the chamber and exhaust ports

I'm not sure if I'll post much info on the ZF could be a touchy subject and I'm prepared for it to blow for the purposes of R&D haha all the info I have found is fairly easy to find, so I can point you in the direction I went if you want to PM me at some stage

Thanks Captain, just trying to give some info back to the forum, and maybe give some other DIYers some pointers

Haha they are -8 Teflon hose wrapped in stainless steel obviously and cost a pretty penny, so hopefully it balances out nicely Keith

Well that's what I thought but Andrew from Technico seems to be confident they will be alright

"800hp is a fair whack of power, but im confident that the parts can handle it. We have several guys pushing similar numbers through the engine mounts with no issues, the couplers are fairly new so im not too sure what the max hp that's been pushed through them yet but they are just as well engineered as the engine mounts so I strongly doubt that you'll have any issues. We also do a solid billet "converter" to move away from the coupling style altogether and run 1350 style unis instead should the poly couplings not hold up to your abuse but I dont think that will be necessary. We would definitely welcome your feedback on how the poly ones cope with your extreme application"

"Id recommend the V series rubber bushed ones for street applications as they are extremely smooth. The P series with poly bushes are a more hardcore mount, and you will notice a bit more NVH. We have a customer running 800rwkw through the V series with no problems at all so both are equally upto the abuse."

Lol it already has suprerpro "sport" blade bushes and rear diff bush and "comfort" side diff bushes... The car is definitely going to get driven regularly and I'm actually hoping it will be aggressive haha so if there's abit of NVH I'm not stressed...

[JETURBO]

Nice progress joe

[Peppy_t92]

Pretty much the biggest restriction is going to be the exhaust manifold and turbo, they will be choking the motor, so I've been having some silly thoughts the past couple days... Gtx42 or 45, custom manifold, set of cams and she will reach for the sky ️