FrankenMoose

Power steering return line is now replaced! Which is a fucking hard job with the engine in, let me tell you. The swaybar is in the way of the nut that keeps the line in the rack. So, the swaybar had to be dismounted and swung out as far as possible, which was about 1 1/2". Took all damn day, but got it done. Also re dipped the STI lip for and preped the front bumper to be installed. Almost ready for a test drive around the block.

I need to document the modifications made to the car and drivetrain before I forget them. Below is everything that has been done to the chassis, engine, transmission, brakes, turbo, etc.: Engine: B5244T3 LPT Block from a '02 S60, Shimmed cylinders, B&B, Ported and Polished, matched Intake and Exhaust Mani ports ENEM Sport Cams CXRacing Forged H-Beam Rods Custom Wesco Pistons with 25mm wrist pins APR Head bolts MPRE Oil Gate Evan's Waterless Coolant converted "Green" 450cc Injectors installed, 650cc Injectors ready for fuel pump upgrade Snabb Intake spacer and Exhaust gasket Samco Silicone Hoses IPD Upper Engine Stabilizer New Bosch Starter XMODEX Rebuilt Throttle Body (Contact-less Position Sensor) Turbo: 20T Turbo with 11 Blade Impeller and 11 Blade Compressor, balanced Intake: Snabb Intake pipe Custom designed 3" Core Intercooler. Custom Pipe routing with Methanol Injection. K&N Intake Mini Filter and Housing Exhaust: Japanafold Exhaust Manifold (from a 2004 S60R) EuroSport Tuning Downpipe EuroSport Tuning Cat Back Dual outlet full Exhaust Ceramic Coating (black with silver tips) New O2 Sensors with spacers. Transmission: M66 from a 04 S60 AWD, refreshed with new bearings, seals and coupler Quaife LSD Kalmar Union Single Mass Flywheel AP Racing Clutch P2 V70R Slave Clutch Suspension: Ohlins 8-way adjustable shocks (front) TME Spring set for Ohlins springs (front and rear) Rear Ohlins shocks need repair TME Strut Tower Brace IPD Swaybar, Front IPD HD Swaybar Links Chassis: New Heater Core and lines Fully replaced rear drive shaft with new center carrier bearing New fog lights GlowShift Oil Pressure Gauge Cooling Mist Methanol Gauge Armrest, Shift boot, Steering Wheel and e-brake boot all custom made to match seats Manual Ball Shifter with Shift pattern and Button IPD Mesh Black Gille 70 Series (no longer available from IPD) WRX-STI Front Lip Sound deadening installed under all panels and rear hatch. Wheels & Tires: Ronal R39 "Ferris" 18x8, powder coated Dark Grey with paint to match center caps (currently only have 1) Bridgestone Potenza Pole Position XL 235/40R-18 tires Brakes: Brembo/IPD Big Brake Kit, all fresh rubber, powder coated Bright Yellow. 330mm High Carbon Discs front Stainless Steel Brake Lines front and rear Porterfield R1-4 Carbon/Kevlar street compound pads I'm sure there's more and I'll add it as I remember. It seems like a lot, but also not that much...

She Moves! The other day, I started her, and turned her around in the garage to do the fuel pump and cat back exhaust. First time it's moved under it's own power in almost 2 years. I did find out the turbo drain has a leak, and the power steering return line has a hole. But, other than that, good day

It was an AEM. Trying to remember where I bought it from to order another.

I removed the Snabb intake to take a look at the PTC a bit closer. Found a hose coming from the PVC feed. According to the drawings, that's the connection that was missing. All good now. Put it all back together and gave it a crank. Started, revved up, then revved down and settled at a stable idle. So damn glad. OK, now to bleed the clutch and brakes, then maybe a test run. Now that it's possibly driveable, time to restart that conversation with Hilton about the tune... Update for #3: I'll have to get another fuel pump. Gave the one I bought for the old car to a buddy that needed it for his monster of a 850 he's building. Now, to remember what that pump was so I can replace it. Probably going to need that before the tune. #10: found a vinyl that very closely matches the wheels, Made by Oracal, 970RA-073, Gloss Dark Grey. I will be ordering some next week. Got a test piece and wrapped a bit of door frame to see if it works, and I think it will be perfect. It'll look different than a matte black for sure.

Vacuum lines in and run. AC Condenser gave a bit of a fight, is installed. The 3" intercooler core makes it a tight fit, but it's in there. Flocking looks good now that it's dry and the excess is removed. Upper dash pad going back in soon. Contemplating switching out the dash speakers for the factory Dyn options as the upgrade. I can't think of any aftermarket speakers I can get that are of Dyn quality for the cost a set of them go for, honestly. While double checking all connections prior to a second test start, I noticed that there is a nipple without a hose on it on the check valve for the PCV system. Not sure what that device is, but its the one that installs on the intake pipe. The wires are connected, the tube to the PCV system in connected, now what the hell is that damn nipple for? Correction, the nipple is on the PTC.

Yet again - I'm taking a walk though the "List O'Things" from the first post. This is mostly for me to reevaluate and track things. So... you know... go look at the NSFW section for a bit. Removing the done stuff, since I can refer to an older post if I wonder what they are: 3 - Install the larger fuel pump that I bought for the old car so that this one will not suffer from low fuel pressure above 4K RPM - Pushing this out until after the car is up and running. Trying to focus on things to get it going and dividing things to GET IT GOING and AFTER IT'S GOING 5 - Repair the one rear Ohlins shock that was damaged when removing them from the old car; install the set, along with the strut brace. - First need to find a good repair shop, then install them while doing the fuel pump - Still waiting to find a shop that will take this on 6 - New hood liner to evict the rodents and their damage - AFTER 8 - Install the Cat back system from the old car and get a new down pipe, since I sold the old one - Down pipe Done, need that cat back in now 9 - Polish up the headlights, or find a set of Jewels. not doing the AMBs again. Sold the old set - AFTER 10 - Get the paint tended to, and do some... selective vinyl wrapping. Gotta make it mine, you know... - AFTER 12 - Figure out the issue with the VVT. Used to get errors under hard acceleration from the VVT. Would like that to stop - AFTER 14 - Since it will not be a work car, Some subs in the back and a full update to the audio system - AFTER 15 - Install the old alarm to add security and remote start; not sure if I'll install the window modules, but I really like one touch up and down windows... - AFTER 17 - New fog lights. Old are cracked. Also install the STI lip, 'cause the front end looks naked without it - AFTER 19 - Oil pressure gauge with Boost installed in custom pod below ashtray - NEXT WEEK - lol next week 20 - Meth Injection installed as well, with guage in pod - In Process 22 - Decide whether to refine the ARD Platinum Tune for better performance, or get a new tune - In talks with Hilton for Stage 3 Tune 23 - Replace the windshield - AFTER ADD: 24 - Door cards are shit. Need to re-laminate the inserts back in and repair the mounts. Also going to get some deadening in there while it's open and some good speakers Nothing like a checklist to keep you focused...

Took a look at the vacuum lines. Found that 1) installed with the check valves backwards, 2) one check valve was blown to shit, and 3) the hose was cracked in at least three places. Hopefully, this is the reason it starts but climbs to redline and dies. So, ordered the most expensive vacuum line I have ever paid for; $100 for the hose and check valves pre-assembled, (EVAP Assembly). Picked up an AC condensor as well, so the AC will work after all. I was going to delay this part until I could find a replacement at a pick a part, but I got a good deal on a new(rebuilt) one, so there you go. Ran the wire harness and vacuum line for the Meth controller though the firewall using the factory location. And, flocked the upper dash plastic (just like the old car). The flocking looks great. It hides the cracks in that piece and makes it just kind of blend in in a way the plastic just... doesn't. And lastly, soldered in the scavenged MAF connector from a donor p-n-p car. Now, the only thing to do is find where that one remaining connection plugs into... Hey, the BBK was purchased a loooong time ago from iPd when they sold it as an actual kit. It came with all the necessary parts to install the Porsche Big Red calipers to the P80 chassis. I had the calipers powder coated banana yellow a few years ago. But, the important part, the adapter bracket, is what you want to look for. Not sure where you can get one now though, sorry.

Relocated the car from my buddies place to my garage. I think this alone will get this car going. Access to it when ever I can, not that I didn't have that before, but I do find it easier to get to my place than my buds.

Long overdue update: Attempted to start it this weekend. All fluids are in, it's ready for a start. I tried to fire it off with the ECU from my old car in there, which has a ARD Platinum tune, but it just would not go. Cranked but wouldn't fire. I really didn't expect it to, but it would have been nice. Anyway, stuck the Original ECU in and it fired up after the third time. HURAAA! But, all was not perfect. It starts up after about 3 seconds of cranking (good), runs smooth (also good), then races to 4500rpm and dies (not so good). Happens every time it's started. I noticed that two of the four wires that plug into the MAF connector have broken off at the connector! I tried to fix it, but there just is not enough wire there to do so. I ordered a replacement connector and a few other odds and ends that are needed to button this thing up. Hopefully, I can get her sorted out by next week. Still a lot of interior work to do done: Door cards, Dash pad, Radio install, etc.; But if I can get her running under her own power, I can get her to a place that's closer so I can do these things in my spare time.

Running low on free time to work on the car. But, I should have a day or two this week. Planing on first attempt at starting this week.

More little things done. Oil is in, Power Steering fluid in, Trans oil in. AC system needs charging, but not until a condenser is found and installed. Snabb intake is installed. Needed a PTC valve to complete and had to dig around for an hour to find the Cam sensor to complete the sensor package. Time to move on to the mounting the Meth system and relocate the battery 90 degrees. Almost there...

Spent the day running and routing vacuum lines, power lines for the Methanol pump, Oil Pressure gauge, reverse lights, intake plenum, charge pipes from turbo to IC from IC to Throttle body, etc. All the little crap that needs doing. Sure does eat up a lot of time. Still need to replace the AC Dryer and find a condenser, as the OE is missing. Going to run without AC for a bit since I really need to get this biatch started and moving under her own power. Get the nice-aties working after. Not too much longer now. Have a list of needs and parts, and a chunk of time to get them in coming up.

It was an issue I ran into after the tune. I was running 750cc injectors and the fuel rail could not keep the 4.5bar pressure needed to feed them enough fuel over 4k rpm, and the engine would stutter and stall. When I installed the 450cc stock injectors, it was fine.

What a mess... At least the 3" think Intercooler will ride again (my design). It's a big mother. Built by BEL Intercoolers of Texas. Getting close now. Just a few more items to work out. O2 Sensors are missing, so need to buy new ones. Vacuum lines need refreshed, same with battery cables. Running without an AC for now. I'll get to that once it's on the road again. Oil Cooler is fitted, as is the pass side axle. SO, the pass side suspension is also complete. All engine mounts are in as torqued to spec.It's down to just checking and rechecking things. And the Intake plumbing and battery mounting, etc. Might be ready for a first fire up soon. Lots to do in the Interior and Exterior, but those can wait until its under its own power.