New World Datsuns...

Turbo attached. I thought the port mismatch was going to be an issue until I realized I was looking at it wrong and it's coming out of the small part into the big part so no need to port match that. which is good because I just traced an outline is getting ready to cut into it when I realized it won't matter. not that it wouldn't be nice to make it perfectly even but in this case it's functional and that's all I need.

So after much cursing, I have the manifold on. Found out the two inboard sandwich bolt holes in the head were crooked. I doubt Nissan did it, but no way to tell. They're not super crooked, but off enough to notice. Good news is the big washer holds it and I'm pretty sure they will still hold without issue. Still annoys me. Probably should have checked all the threads. Re-tapped those two, no other issues save the manifold is a bitch to tighten with all the heat shields in the way. Really need a set of tap sockets. I left the heat shields on because turbo. Lots of heat.

I also found the new turbo inlet is 3" and the cold side outlet is 50 mm. Seems odd they wouldn't have done it at 2" but oh well. So now I need to figure out what type and how I'm going to run an intercooler. I have a collection of piping, but I'd like to make it as simple as possible. Still thinking about a water to air intercooler, but haven't decided yet.

The other thing I need to do is figure out what air systems I want back on. The valve cover breather goes to the pipey thing that looks like an EGR but isn't next to the other vacuum pressure can of unknown function. I'm probably not going to use the original non-intercooled pipe. The heater assembly has a collection of air dinguses that go where that top-side pcv? sticks out at an angle. Right next to it is a smaller outlet, those both went to the same pipe that went from the air bleed idle deal to the turbo pipe. The valve cover section went in front to the fresh air side on the air filter tube.

Pretty sure I can get rid of all of it and just pipe the valve cover breather into the intake and hook up the bottom block breather to the pcv on the bottom of the intake. No vacuum idle control needed, the MoTec doesn't need any of it anyway. But I also want to not make any additional problems, and removing systems that I'm not 100% sure if their function affects other things makes me a little bit worried. Guess I'll just have to try and see.

Here's what it looked like originally:

Get yourself some copper jam nuts for the turbo manifold. Copper wont seize to the stud, and the extreme heat turbos make lead to seizing conditions.

For metric hardware, I use belmetric.com. They carry a lot, and decent price.

That's a mighty fine idea! If I hadn't just gotten it reassembled, I totally would. As it is, fuck that thing, it's not coming off unless the engine explodes, lol. Next build or maybe the truck when I put a turbo on it. Now that you mention it though, the new Chevy Sonic and Cruze shitboxes use copper nuts. Too bad the mani-turbo design is shit and the wastegate always cracks.

Alright kids, so I didn't get the intercooler installed yesterday. Little issue with fitment. Further issue with a smaller intercooler. If I'm going to use it for hillclimbing, I'm going to be full throttle all the way, which means I need a big intercooler. I'm trying to find another option that fits easier but is still large enough to cool the air charge. I did get the valves adjusted, throttle body on, injector rail attached, and the oil drained and threw in some fresh Amsoil. My buddy is a dealer, I've started using that in the racecar and the wagon, as opposed to the Schaeffer's I was running. Going to see if another buddy of mine has an intercooler today, maybe hit up pull and save, and see if I can get something rolling without spending more money.

Slowly but surely you’ll get it

Thanks man! Somedays it seems like it's cataclysmically slow.

So I didn't realize I could still get the injector base pedestals new, but the Z store has them in stock! I have a few cracked nasty ones on the Z, these were about 5 bucks each, super cheap for new bases. I'm thinking I've seen metal ones people have made which are nicer, but cheap and easy does the trick for now. And really, I'm probably not going to put them on until I have an excuse to pull the injectors again, which I hope to not have to do. But, if I do, then I'll have replacements!




Here's the intercooler I got off ebay, now with outlets moved 90 degrees for easier piping. The downside is it still doesn't quite fit and because of the way it's designed it can't be shortened easily. Just won't work. So the option now is to cut that front frame rail for clearance and weld a step in it, OR hang it off the front grille boso style. As much as I don't want that, it would be substantially easier. I'm about to go out in the garage and see how I want to make this work.

We all know I'm not one to take the easy way, lol. This section is double walled, fyi.

Shiny death wheel says a little bit louder now!!

Almost there!!

Finally have the hole fettled enough to get both intercooler hoses through the core support. Need to make a template now and box in the section I just cut open. It's probably strong enough anyway, but I'm already there and it's the proper way to do it. Also banged the front edge with the hammer to make a nice ramp. Should have barely enough clearance to put a piece of rubber on the bottom to isolate the intercooler from rattling against the frame rail and fit the upper hose without killing the already thin top portion of core support.

Damn tight fit. This is after moving the oil cooler over a full inch. It's looking like it should fit for packaging though. As far as the air filter off the turbo, either I'm going to need to make a duct underneath to funnel cool air, or run it up and cut another hole in the hood with a NACA duct. We shall see.

After a little bending with the hammer it should fit right in and weld nicely.

Now to see if I can manage to clear up enough crap to get the welder over here.

I was wondering why I was having feed issues ran out of wire looks like a good time for lunch.

Went to Napa got some welding wire and a few other odds and ends and we're back in action! I do think I had a crappy ground the last panel I welded on so we'll see if that improves on the new spot I have now. Getting ready to put the last panel in to fully box in the section I cut out and I even put little tiny speed holes in! it's actually so I can run fluid film back there because I didn't have any well through primer it's a little coating of wax will keep the rust away.

big thanks to project Binky for showing me the way as I'm using 3x5 cards and cutting them into shapes and then transferring to metal and cutting them out with the grinder.

Not my finest welding but not terrible at least. Having a real problem getting a nice ground on this. either way it's done and now I can actually start mocking up the mounts for the intercooler.

So you know when you have that oh s*** moment? Yep I'm there. I got the flat black on the section I cut out and figured while it was drying I should hook up the turbo oil drain that I didn't have hooked up. It was really a pain to get it to go in and I couldn't and now I know why.

the two options are attempt to rotate the turbo with it mounted which is a giant pain in the ass. Or remove the turbo and rotate it which is a giant pain in the ass. Or accept the fact that it's about 20° off and kink the tube and roll with it.

I'm calling it quits for tonight. I'll think on it with a good night's sleep.