Kozworth's turbo build for gfest!!

[Kozworth]

Hello r3vers,

I was originally Poor Adam when I came to the forum from the vw world. I parted my first e30 due to rust and to fund some turbo things while having extra parts. This is my first tune/engine rebuild/ turbo setup. I am currently in advanced engine diagnosis so a lot of the work will be done tues and Thursdays in class.

Just a little bit about me, I am graduating from college with an associates in automotive tech in may. I have a brief background in mig/stick/tig welding.

Outside of cars I enjoy:

Girls with glasses, fishing, camping, billards, etc.

The first e30 that started the craze:



Anyways back to the build. Picked up this eta may 2012, daily drove it for a few months..


I liked the torque of the eta but really saw the body as a good candidate for a project. I've never owned a turbo car, and figured it would be a great learning experience eithor way.
So with the engine removed out of the sedan and the coupe being parted, I picked up an e36 to daily.

Got the block o ringed and pistons mounted from fisher machine shop in Edison nj. We just cleaned it and ready to put the eta crank and check end play and clearances.


So got the wrong pistons on wrong rods. I mixed up what I told the guy at the shop. So basically eta pistons on I rods.


Crank is torqued in, perfectly in spec.

Got the i pistons on e rods back from the shop. Had to put clips in the wrist pins.. Blood shed from a screw driver slipping.. It's all good!

I was bored so mounted the turbo on the parts car to check clearance for down pipe.

The sedan sits waiting for the engine and body work.

One of two rust spots. The pan was rotted. I might redo to do a side exit.

Got to bead blasting at school.






And the head was pulled for the 885 swap.


The setup:
Oringed block, arp, stock gaskets, h1c, tial bov/wg, whodwho ms, 3 inch turbo exhaust, 42lb green tops, f1 racing clutch with pp and 323 lightened flywheel, and more to come.

Looking for 300 whp. I need this done by g fest!!!

Upcoming: order rings, assemble engine, paint the blasted parts, and arch repair!

Thanks for checking up on my project! Should be updated regularly and if you have any input I'd be glad to hear it!

-kozworth

[Vtec?lol]

DO WORK!
Looks good man!
I've always wanted a boosted m20

[Kozworth]

I'm trying and honestly if it fails at least I learned a ton between hands on and via r3v. You just really got to save a lot more then I did and read all the time! I don't mind.

[travish325]

I didnt read anything past this.

[Pootis]

Looks like a good plan man I look forward to seeing progress

[ZM Blue Devil]

Keep it up bud, looking forward to seeing you at Gfest or sooner :)

[yberther]

I didnt read anything past this.

Lol this is mostly what I absorbed as well.

[Kozworth]

So today I decided to conquer some body work while I sort out some engine building issues (explained below). My good buddy helped me and guided me through the process, and I feel it came out great. The car really has mostly dings/dents, but the major rust is the drivers rear arch, floor pan (crappily rewelded, will fix up).

Welded my vband flange to my 2.75->3 inch downpipe



Figured id weld some arch rot





Not pretty, but strong


She sits outside, so a little more grinding and welding, then she will be ready for a skim of bondo.

Ripped off the trunklid lip for a cleaner look and some dough in my pocket

Two down, a few more to go

Bay needs some space freed, power washed, and some pointless brackets (stock afm bracket, early coolant tank bracket, etc) deleted



The issue with the engine is this. Braught a box of I and E pistons on rods, confused the machine guy and got the E pistons on I rods for 70$. Then got that flipped for 50$. However, the rod caps are currently MIA. I do not want to go find more eta rod caps, dismount/remount the pistons a 3rd time, bore and hone the rods to spec for .2L of displacement. Forged rods/pistons would cost too much, and in return would have to get a forged crank.

I still have the 2.5L bottom end chilling in my parts car, I am going to gut the internals from that and swap them into my 2.7L o ringed block. While all this crap could have been avoided with a more planned method, it has taught me to not jump the gun and throw my (little ammount) money at random ideas.

Coming Up Tues:
-Whole 2.5 internals into the o ringed block, HG, studs, and hopefully the Longblock togather. The rest should be finished Thurs, and engine in that weekend if all goes well.

[Kozworth]

Long time no update! Well I was in the midst of selling the e36 to get a truck to transport all my parts easier and to fish with!

I started yesterday with just a short block and arp ready to go. Had to make a quick run thru rush hour traffic to GPS for some head bolt washers (thanks L).



My buddy who has been the major extra set of hands/parts washer!

Got the head settled and its starting to look like an engine.


So really rigged this guy in the bed and ready to get this car finally rolling.

Had to drop the pan a little to fit rear main on

F1 stage 3 racing clutch with lightened 323i flywheel





Almost gave up for the night it's 2am and work at 8am. Timing belt was being a pesk. I've done two m20 belts before maybe it was just late. But my last try I got her on tdc all buttery and whatnot.

Got her in pretty flawlessly, added some manifolds and whatnot.

It's 5 am time for 2 hours of sleep. I consider it a successful day since I did my first head gasket/clutch and 3rd timing belt.

I have a few more m20 things to tighten up, then it is wiring and all turbo fab work. At least the easy stuff is out of the way!

[Murtosa]

lookin good. this is what im going for bu i may be staying full m20

[Kozworth]

Right now it's pretty much full b25 but with an oringed eta block. A lot of stupid mistakes that costed money and time but that's how you learn I guess!

[Kozworth]

The plan was to get a lot more done today but it was one of those off days. Where I had left off was all the post IC piping needed to be fitted and ready to be welded along with the BOV flange.

I really do not care for this boring airdam, and figured since it wasn't mint or really sellable I would go to down to cut it around the intercooler piping. Kinda going for a sleeper look, I am also paranoid to hell that people will steal this thing, since its my first real car build.

I read a lot on IC sizing, and basically threw a few inches onto what people run so I wouldnt have to buy another. I know there will be a hair in lag, but whatever.

Mockup. What intercooler?


The only issue with this is I am very curious to see if this is restricting a lot of airflow, as it looks like it might be. I still have the aux fan, and was wondering if anyone thought that if this was restrictive maybe wire in an aux fan somehow. Just throwing that idea out to get more cool air over the ic.

Pretty happy with the plumbing since its all pretty much straight and not tangled around a bunch of stuff, and also remotely hidden. Now I have a huge hole on the drivers side where the airbox is. I could acutally change the oil sensor in the pain from uptop haha.

.

I need to go to a Guten run to grab some various hardware and whatnot, and get this engine tightened up. With my hectic schedule, I would really love to have this guy fired up before my birthday May 2nd, but no promises on that.

[Mr. Tasty]

what are you using for engine management?

[325ix]

Really like the build so far. Can't wait to see what kind of numbers you put down.

[Larzzz]

cant wait to see more!