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Discussion Starter #1 (Edited)
Hello all,

it has been a long time coming, but at last, the progress is happening thick and fast. I'll be chucking my story and some supporting pics in here to keep you entertained. Hopefully this will inspire some of you to post up your projects and stop this forum from being completely dead.

To keep this thread contiguous and tidy, please DO NOT POST HERE. I have asked the mods to delete posts in this thread for that reason. Save them the work please.

If you are reading this, you may as well let this page load and read through it, but for the subsequent pages, unless you havent seen it before and have dsl, i recommend searching for what you want to see in this thread :

http://www.mx6.com/forums/fe-dohc/199610-freds-master-fe3-index-thread-please-dont-post.html#post1918523

That thread contains every post directly linked and indexed so you can search for anything you are interested in without opening extremely large slow to download pages of this thread. It also contains a full listing of everything of interest to an fe3 owner/modifier. It should be your first port of call anytime you need to know anything.

here is the comments thread :

http://www.mx6.com/forums/showthread.php?t=182352

enjoy!

Fred.
 

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Discussion Starter #2 (Edited)
I guess the first post should be a collection of links to all my threads from all the years. they make up the balance of this project. So this post will be for that. I'll edit it as i find them.

List of threads about my project :
The bell housing find (note this is only good for one type of R box, there are twisted and straight) :
http://www.mx6.com/forums/showthread.php?t=134392
Max lift on stock bits :
http://www.mx6.com/forums/showthread.php?t=133181
Different intake manifold discovery :
http://www.mx6.com/forums/showthread.php?t=153444
FAQ revamp suggestion (still needs to be done. if i could edit it i might give it a go.) :
http://www.mx6.com/forums/showthread.php?t=158607
The beginning of the end (the truck drives again after a long long hibernation, and a LOT of welding) :
http://www.mx6.com/forums/showthread.php?t=159350
The intercooler purchase :
http://www.mx6.com/forums/showthread.php?t=177011
Where I found my motivation to get stuck back in after working too much for too long :
http://www.mx6.com/forums/showthread.php?t=178953
Turbo and bits :
http://www.mx6.com/forums/showthread.php?t=179272
Wastegate problem :
http://www.mx6.com/forums/showthread.php?t=179342
The sump mods :
http://www.mx6.com/forums/showthread.php?t=178777
VR6 springs dont fit without mods!! :
http://www.mx6.com/forums/showthread.php?t=133131
Manifold design files (stopped working, if you wanna host em on mx6.com or somewhere, let me know, i still have them.) :
http://www.mx6.com/forums/showthread.php?t=177570
What not to do when swapping springs on a whole engine :
http://www.mx6.com/forums/showthread.php?t=180707
Bottom end factory torque with link to head torque (Thanks a million dutch) :
http://www.mx6.com/forums/showthread.php?t=181997
The telstar purchase :
http://www.mx6.com/forums/showthread.php?t=179774
How to clean your HLAs (the original one and only) :
http://www.mx6.com/forums/showthread.php?t=106184
The gearbox :
http://www.mx6.com/forums/showthread.php?t=154476
The first fe3 smokey :
http://www.mx6.com/forums/showthread.php?t=182313
temp sensor resistance/temp graph :
http://www.mx6.com/forums/fe-dohc/140985-coolant-temp-sensor-table.html
turbo flywheel and clutch in an na tranny/bell housing :
http://www.mx6.com/forums/1g-mx6-general/156505-turbo-clutch-fit-n-tranny.html
fuel system thread :
http://www.mx6.com/forums/fe-dohc/196503-ultimate-fuel-system-design-discussion-diagram.html
antilag thread :
http://www.mx6.com/forums/fe-dohc/194674-proper-antilag-thoughts-comments-suggestions.html
megasquirt thread :
http://www.mx6.com/forums/fe-dohc/194372-big-megasquirt-info-thread.html
build thread post :
http://www.mx6.com/forums/1756303-post7.html
crank case vent pcv
http://www.mx6.com/forums/fe-dohc/188869-crankcase-ventilation-discussion-sort-survey.html
fe3 humour AKA take the piss out of myself and fraud :
http://www.mx6.com/forums/fe-dohc/196077-fe3-humour.html

will edit as i create new threads about different aspects.

enjoy :)

Fred.
 

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Discussion Starter #3
Yesterday and today were big days for the ute project, yesterday i took the old engine and trans out, and then slipped in the new box. I bolted a spare block and head up with the sump thermo housing and CAS on it, and found that i needed to beat in the firewall a bit to make the CAS fit. I went ahead and did that and also whipped the bottom corners off of the sump to clear the chassis in a place where i had forgotten i had left less than the average amount of clearance. here are the pics :

placeholder to be posted.

Fred.
 

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Discussion Starter #4
i'm going to keep the story rolling and add pics later.

this morning i dropped into abc in taka and ordered my clutch.

1900lb pressure plate (stock is supposed to be 1300 or so for the f2t)
luk friction disk with large dual springs and normal organic material
new bearings.

i also ducked into bnt and picked up a large simota air filter cheap, good, pretty. what more could you ask for. 190 across the base, 150 neck and 120 across the top. dual cone type.

this evening i seperated the motor from its auto box and removed the torque converter and flex plate.

i also tried the filter in the place it will sit. good clearance all around to suck nice cool air from all directions.

just need the flywheel modifying before the engine can go in!!

fred.
 

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Discussion Starter #5
so, this morning i ducked out and did a couple of things to the engine. i forget exactly what. this arvo i picked up the pressure plate and brought it home. i cut the ring gear off of the flex plate ready to fit and weld to the f2t flywheel as soon as it gets turned down for it. i went to a mates with a BIG air compressor and sand blasted my sump welds ready for a lick of paint. i organised some parts from my cous at mazda, and sand blasted the trailing arms i got out of a townace van that i need for cert because i have used 60mm lowering blocks. i also came up with a cunning idea :

having been unable to find a weld on flange for the vband outlet on the holset, not here, not on ebay, not anywhere... i realised that a machined pulley off of some engine or other will be correct or close to the right diameter, and i can cut it down and bore it out for the 4" down pipe. have to go looking this weekend.

off outside now to put some primer on all the sand blasted bits... before they rust.

fred.
 

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Discussion Starter #6
ok, so i painted all the bottom end gear with high temp primer, and the trailing arms with ordinary zinc primer, i measured the bell, pressure plate, flywheels, ring gears etc, counted, and measured the bolts/threads for the sump considering its all different on mine now... and will go looking for bolts and bits in the morning before work.

the thead that isnt mine, that i posted in ever so long ago about the flywheel and bell mod is this one :

http://www.mx6.com/forums/showthread.php?t=156505

i'll update and add pics when i do the mod this week or early next.

fred.
 

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Discussion Starter #7
got up before the alarm at 7am this morning, headed out the back and put some black hi temp enamel on the sump flange, and wiped the primer off the mating surfaces of the mains braces with some thinners, went out to the engine and filled the ports with socks and whipped off the intake manifold. went and bought and ordered bolts and cap screws to hold the sump on with, picked up a section of 4" pipe to size my turbo outlet fitting to. time to sit and work for X hours until i get home and do some more "ute" work.
 

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Discussion Starter #8
bought a 35mm mandrel U tonight and started work on coolant plumbing. also diced up a U for the manifold, and modified the alternator bracket to not be an engine mount and to be a coolant pipe mount. i'll pickup another U and a straight bit tomorrow and start some welding and mounting. i have a nice genuine two valve thermostat on the way along with some other genuine parts from mazda. tomorrow night along with that i'll be painting the sump and fixing some rust in a fucked old corolla wagon for a mate that did 162kph on skis and crashed on one run at about 120kph and broke a few ribs and a thumb. looking forward to the weekend, i'll have the motor ready to go in bar the flywheel that i'll be turning up on a mates lathe on monday night to match the small ring gear.

i promise, i'll put up some pics soon :) soo much to do, no time...

fred.
 

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Discussion Starter #9
grabbed some more U bends and pipe today, and picked up a new rear main seal, new thermostat from a bp, new shifter boot, two oil pump pickup gaskets, and an O ring for the CAS. staff price at maz = 1/2 retail, but still pricey for what i got. the correct thermostat has rolled over to a f201 part number, the old ones have been superceded. the only difference is in the brass bit that comes out to touch the sensor, but as i wont be using that anyway, it is irrelevant. it has the double valving like the one dutch pictured. both do. it was my suggestion to check the other dohc motors. and its worked out to save me about 15 bucks.

i'll take and post some pics tonight if i get enough done. thing is i forgot a work meeting, and have the roller to do, so may not get a lot done before its too late to make too much noise...

fred.
 

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Discussion Starter #10
ported out the thermo housing a little to ensure the thing can open 100%

the bp05 part is slightly longer in the back and thus will not quite clear the housing when fully open. strangely its even worse in the fe3 housing, and even though the fe3 one is shorter, there is no way it would open all the way in there...

i also radiused the edges while in there for more coolant flow :)

i painted the alt/coolant mount with black engine enamel tonight too.

not very productive, but got the corolla done, and got home at about 7:30...

tomorrow night will be better!

i guess i better chuck up a photo or 10, so heres an air filter and other gear... ok, i went a bit nuts and put most of them up... so in the next post.

fred.
 

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Discussion Starter #11 (Edited)
yay, pics at last.

all ready to pull


pulled


empty


a sight for sore eyes :


sump etc in to fit


doesnt fit so well, oops i forgot...


THERMO HOUSING DOES THOUGH :p (i'm so childish ;-))


new engine pulled and ready for final lift.


sump rework begins look at that penetration


how it looks sliced


more in next post if conn holds out and my patience with it...

fred.
 

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Discussion Starter #12 (Edited)
the sump welded up again






coils and wires and igniters


big arse air filter with 150 mm inlet/outlet


donor flex plate that surrendered its ring gear


clutch friction disk with four rivet per post attachments.


and some more, wiggling the lines under the house helped the conn no end...

fred.
 

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Discussion Starter #13 (Edited)
final post for tonight :

flywheel with new small ring gear on top


pretty exedy hd 1900lb pressure plate




sump sand blasted to make sure paint sticks well


primed with high temp zinc


primed toyota trailing arm


fu.ck this i'm off to bed.
 

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Discussion Starter #14 (Edited)
clutch barely fits into the bell housing, but will be ok with 2mm machined off the outside edge.


primed braces


enameled gasket surface


alternator bracket was engine mount now coolant mount






stock and f2 thermo housings with thermostats and seals etc


thermo ported slightly


these are the last pics you get till sufficient comments roll in :)

fred.
 

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Discussion Starter #15

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Discussion Starter #16
today didnt go quite as planned...

spent the first part of the morning having a bit of humour trying to pass a wof. they have just brought in a new "if you can see smoke, it fails" measure. thats the state of emissions testing here. my mates corolla failed on this, having over 200k on the clock, and not being well looked after... it has a little white smoke after idle and a little bit while giving it a bit of shit. not too bad, not billowing... still FAIL they said. sock up the tail pipe i said. and sure enough, it filtered out the smoke, and didnt restrict it enough to stop it running well. in we went, and i got the whole thing on video. bloody funny. esp when we took the pin out and gave it a rev! shot the old white sport sock about 30 feet across the road with a pop :)

packed up the tools next and headed for pick a part. spent till about 3pm there and then eating afterwards, picked up the following bits :

radiator hoses and clamps
plastic fans (twin 12" off a mondeo)
injector clips
surpression caps for the coils
a pulley to machine into a vband flange (yes i found one that will work mint)
an oil cooler from a audi (nice unit, but may not be able to use it because of fitment issues and time/$ restraints.

reorganised the tools, knocked the small ring gear off of the small flywheel, packed rings, flys, pulleys, turbo, verniers, cutting fluid etc up, and headed to the auckland fsae workshop to turn down the flywheel for the smaller ring gear. slow going. so far its lost 0.8kg to 9.7kg from 10.5kg. that weight is lost going from one ring gear to the other, i havent removed material from the back explicitly to lighten it yet. but i will. i'll also be removing material from the outer rim to allow fitment to my small bell housing. it might come down to about 8kg in the end, all from the outer edge. a significant inertia saving.

i'll get some pics up after i go outside and secure my tools...

fred.
 

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Discussion Starter #17
updated the clutch/flywheel thread here :
http://www.mx6.com/forums/showthread.php?t=156505

images here :

the lathe :



The ring gear seperated and a choice of two small ones to replace it :



fitted up on the lathe :



turned down for the new ring :



0.8 kg of swarf :



there ya go, inline images :)

fred.
 

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Discussion Starter #18
some pics of this week ends work :

block all cleaned prior to taking sump off :





coolant hot out pipe welded in place (yucky welds... settings wrong... dirty pipe...embarrassed...)







dirty japanese bastards









put away for the night :



the sump finished and ready :





tune in next time for more exciting pics thrust forward into your face whether you want it or not by popular request :)

fred.
 

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Discussion Starter #19
monday night was spent under the engine cleaning the jap filth out, my trusty GIRL friend (got it sick?? ;-) ) helped me for four hours toothbrushing the main caps and bolts and robs braces. a lot done, but not as much as i'd hoped.

last night was similar, finished cleaning down below, fitted up the oil cooler, knocked out the rear main, tapped the block for a bolt to hold the spacer and windage tray, and just about got blown out of the car port...

this arvo i am going out to the uni shop again to finish the flywheel, if the wind isnt too bad, i'll try to get the engine in tonight. once and for all, but i wont rush things... so we will see. still quite a bit to do. but very close.

i have some pics, might post em up after work later. or at 2 am with an engine in for good.

fred.

fred.
 

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Discussion Starter #20
the flywheel with the ring gear shrunk on, covered in condensation, and still at about -20...



my trusty assistant :



half done with the cleaning :



possibly the only photo in existance proving that the skyline can go between stopped and running and be somewhere below 5k in the middle!! :



that was monday nights efforts...

next post tuesday...

fred.
 
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