Member Profile - It's a nice day for a white wagon!

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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Tue Nov 22, 2016 11:06 pm

dr20t wrote:Really liking the updates and especially that cluster redesign

How did you make that ?


Dissasemble the dash cluster
Hi Res scan of the gauges.
Use inkscape (or other vector program) to trace/rebuild the basic shapes
Spend hours obsessing over the details
print a shitload of test copies
print the main coloured version on a transparency, print a backing sheet on normal paper, glue them together.
Cut out
fit.
Remove huge sections of plastic from the backing in the cluster.
Remove the stepper motor for the coolant gauge and superglue on a different stepper motor.
Probably some other stuff, but that's the gist :)

bigBADbenny wrote:Sensational!
Thanks for keeping the progress reports coming :good:
So you deleted the oil warmer thus the adaptor fitment issue?

yeah stock is gone. I could have just left it, and should have but I wanted an oil cooler. it has been a MASSIVE headache.


MASSIVE update incoming....

O2 sensor fouled the 6MT because it's much bigger:
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Got the punch stuck in the bloody roll pin took 30 minutes to get out
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Cut out the diff carrier bolts with an angle grinder. I could not get those fuckers off:
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In goes the new shafts, hubs and R180, with Garage KM1 Inserts and beatrush by laile diff carrier.
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Exhaust on and looking good
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But because the turbo is canted back 10 degrees, the dump pipe is way off
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... and it fouls the driveshaft
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So we cut it to see the difference
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Do some more cutting, get a section of pipe and mock it up
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Fab up some oil cooler brackets:
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Starting to sort out the hose mess
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More bracket fab, this time for the oil catch cans
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Picked up a K&N filter from supercheap after I realised the trust one physically didn't fit in the gaurd.
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Upgrading the earths
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Mocking up the post turbo piping
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Dump pipe welded and now fits!
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Turbo piping fits too
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Moved the WBO2 down
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That bottom nut on the turbo is a doozy!
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Little bit of cutting to get the spec b pedal
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Wiring up the stereo
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Add wiring to the stereo harness for the middle gauge setup
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Repin the daewoo plug for the McIntosh amp
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Gauges look amazing!
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Move the intake to the gaurd
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Cut the front bumper to fit the FMIC
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Dremel the foglights for the LEDs
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Bugger it, going to flip the core.
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Foglights!
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Wires! Loom for all the sensors.
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Picked up a Kicker Comp S 8 and some sound deadener
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Custom Trimmed inner kick panels look amazing:
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MAP sensor cracked hose
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Injectors leaking at the base, ended up running a top O ring, as well as a square O ring to get them to seal.
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Red stitched door grabhandles!
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Rear wheel fouls even after rolling. Neeeded to cut off some of the plastic cover, remove the cover, and roll the very forward section as well.
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Oil cooler leaking.
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Replacement sandwich plate leaking
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New sandwich plate would NEVER WORK due to the stupid design!
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Picked up some new fittings for the original plate:
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IT DRIVES:
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Grabbed the piston out of the old engine: wow
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Did the front wheel bearing
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Video:

https://www.youtube.com/watch?v=jXN3Wb_GiYs

Where we are at now:
Had it tuned, but it only made 180kw on 15psi, and full boost at a horrible 5200 rpm.
Following issues need looking into:
* Running out of fuel in the top end (Possibly pump or O ring issue)
* Tighten up BOV to ensure not leaking
* Suspect up pipe to turbo leak
* Increase wastegate preload
* Can't get over 15psi, need to change wastegate spring.
* Still oil leaks (oil cooler, plus it seems to leak a bit out the cam seals. Ugh.
* Front engine cover broken (I broke it) I should replace it
* Radiator upper hose is dead, ordered new upper and lower hose.

Slowly but surely I'm getting there.

Edit: Edited first post with all mods - it details the gauge system, but it's not finished yet.
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Re: Member Profile - It's a nice day for a white wagon!

Postby jslayz » Wed Nov 23, 2016 12:32 am

Massive progress!!
Keep tracking down those issues
CURRENT - ATP GTX 3576 - 22psi - 283.7awkw
OLD - Dom 1.5Xtr - Last dyno 254ahkw, previous 238ahkw, first 224awkw.
My journey thread: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523
My Lib Pics here: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523&start=570#p370656
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Re: Member Profile - It's a nice day for a white wagon!

Postby Gtb08 » Wed Nov 23, 2016 10:57 am

HardwareBoB wrote:
dr20t wrote:Really liking the updates and especially that cluster redesign

Had it tuned, but it only made 180kw on 15psi, and full boost at a horrible 5200 rpm.
Following issues need looking into:
* Running out of fuel in the top end (Possibly pump or O ring issue)
* Tighten up BOV to ensure not leaking
* Suspect up pipe to turbo leak
* Increase wastegate preload
* Can't get over 15psi, need to change wastegate spring.
* Still oil leaks (oil cooler, plus it seems to leak a bit out the cam seals. Ugh.
* Front engine cover broken (I broke it) I should replace it
* Radiator upper hose is dead, ordered new upper and lower hose.

Slowly but surely I'm getting there.

Edit: Edited first post with all mods - it details the gauge system, but it's not finished yet.



I know it doesnt seem obvious but check your vacuum hoses from the TBCS to the turbo

I had my car dyno tuned with matt from kido. tuned and couldnt get it above 15psi either. Matt suggested a spring because the wategate was fluttering. I replaced the wastegate actuator with a 14psi unit Hoping it would help
Got a retune and thats when Matt picked up the hoses were arse about. Changed over and boom!!! 17psi in only sport mode straight up

Ran out of tune time and will need it redone in december, but will likely refit the original wastegate actuator. If you do need one i may have one available....
2008 OBP Liberty GT SpecB ATM - KOBE MSPORTS SILCONE INTAKE & MAF HOSES - TUSPEED 3-PORT BCS - AVO DUMP 160 CEL CAT - KIDO TUNED - ATM TRANS COOLER - KOBE MSPORTS BoV - KOBE FUEL PUMP - WG PORT N POLISHED VF52 TURBO - MISHIMOTO TB HOSE - GReddy DUAL CATCH CANS - CUSTOM REDBACK MUFFLERS - RED STITCHED LEATHER WRAPPED STEERING WHEEL - DBA T2 SLOTTED ROTORS - XYZ SS COILOVERS - CUSCO STRUT BRACE - quarter 13.42@100MPH
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Re: Member Profile - It's a nice day for a white wagon!

Postby Kekotic » Wed Nov 23, 2016 4:47 pm

Great write up Matt! Really interesting to watch your build progress.
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Tue Jan 10, 2017 11:21 pm

UPDATES!!
surface rust on the filler neck in the fuel filter whilst fixing the fuel pump...
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New radiator hoses, New timing covers, New cam seals
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.. proper manual ones.
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The gauge system lives!
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Go out on the cruise.. Oil cooler line wasn't set up right after I changed the timing cover (had the radiator out) and the line melted on the headers. Had to remove oil cooler on the side of the road. Worked perfectly after that.
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More work on the gauge system
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Dead AC tensioner, killed the belt.
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BOV is totally fucked. Also, it turns out the FLANGE for the bov is ALSO fucked. I cut the whole thing off.
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Gauge work continues
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Rear wheel bearings! All four are now replaced.
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Quality BOV replacement, GFB Mach2 recirc.
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New BOV pipe welded.
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Install it, get my old friend the boost checker.
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I found a leak
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And... another one.

https://www.youtube.com/watch?v=DyYfZq-72lI

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Back to the welder tomorrow to get the pinhole tacked up, but not a bad result, the intake system is otherwise holding 25+ psi static, so once I get the pinhole fixed it should FINALLY be ready to work properly. I still haven't finished the gauges or fixed the oil cooler though, that's a job for another day.


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Re: Member Profile - It's a nice day for a white wagon!

Postby bigBADbenny » Wed Jan 11, 2017 12:42 pm

Hair spray the cooler pipe ends to help lube and seal the silicone, can't hurt tip ;)

What's correct boost leak test procedure?
Under 1psi, oil cap off???
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Wed Jan 11, 2017 3:53 pm

bigBADbenny wrote:Hair spray the cooler pipe ends to help lube and seal the silicone, can't hurt tip ;)

What's correct boost leak test procedure?
Under 1psi, oil cap off???

That's not a proper boost leak test - That's a good intake leak test, but step 2 is remove the turbo connection and stick your boost leak checker in the pipe, and crank it up to as high as you need to test. I needed to make sure it wasn't leaking at 20+ psi, and I had leaks that started at 8. Can't reproduce those when pushing air in the intake, especially with non pressure sealed catch cans.

Obviously with a TMIC that has a flange this is very difficult.
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Re: Member Profile - It's a nice day for a white wagon!

Postby bigBADbenny » Thu Jan 12, 2017 6:08 am

Righto, so seal the inlet tract from air inlet to outlet to turbo and give it some :)
I guess pressurising the inlet mani or crankcase for leak testing has to be done at low pressure to keep the cam seals in...
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Fri Jan 13, 2017 1:22 pm

* Got the pinhole tacked.
* Refit everything . Test, BOV reference pipe blows off. Find a hoseclamp for it.
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* Intake holds until 30psi, when injector seat seal starts going - I can live with that, I won't be near 30psi when running.
* Go for a test drive. Realise that somehow when I changed the wheel bearings I've knocked the backing plate for the left rear wheel so it touches the (ugraded/larger) rotors.
* Remove wheel, bend backing plate, Refit.
* Go for another test drive. Still only makes 9 psi. (but drives well, no issues - better, but WTF)
* Unplug the wastegate actuator. Careful test - makes more boost!
* Plug it back in and wind in some duty cycle to the boost solenoid. makes 12 psi. Feels MUCH better.
* Do some research, find out that other people have had the exact same issue - MAMBA/Kinugawa piston actuated wastegate springs are about half their rated boost. See viewtopic.php?f=2&t=34266

Nee to futz around with the fuel pump again (fuel pressure drops right off up top and it's at 85% duty cycle), but after that I should see some actual power out of this stupid thing!
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Re: Member Profile - It's a nice day for a white wagon!

Postby Spec BSC » Sat Jan 14, 2017 1:42 am

WOW well done for keeping at it.
The first engine died after eating to much CAT
The second engine died of a broken piston
The third engine is in the car
The fourth engine is in the machine shop

So far: Rotrex Supercharger (16 psi) with WTA intercooler,DW300c fuel pump,565cc Pink injectors
Producing 431bhp and 350 lb/ft torque on the Rotrex SC not finished yet
Raptor headers, 75mm Milltek exhaust with Quad tips,
Custom made 4032 forged pistons by JE Pistons, forged conrods, Exedy Clutch
K sport 8 pot front, 4 pot rears all on 330mm discs, Hel brake lines
Meister R coil overs, Whiteline 21mm rear ARB, Perrin end links and strengthening brackets
Complete Whiteline kit for the front suspension including steering rack
One off Carbon effect Front grill, Carbon lip spoiler, Exterior De-chromed, LED interior light conversion.
Recaro Leather front seats with all functionality.
Waist spoiler, Smoked rear lights,, LED sill plates, LED sidelights
Prodrive PFF7's 18x8, in Bronze shod with 235/40/18 Goodyears.
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Re: Member Profile - It's a nice day for a white wagon!

Postby jslayz » Sun Jan 15, 2017 2:32 pm

Spec BSC wrote:WOW well done for keeping at it.


Stay the course, you will be rewarded :)
CURRENT - ATP GTX 3576 - 22psi - 283.7awkw
OLD - Dom 1.5Xtr - Last dyno 254ahkw, previous 238ahkw, first 224awkw.
My journey thread: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523
My Lib Pics here: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523&start=570#p370656
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Re: Member Profile - It's a nice day for a white wagon!

Postby bigBADbenny » Mon Jan 16, 2017 7:05 pm

Hardwire fuel pump or upgrade wiring / add relay to fpcm a la lgt?
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Re: Member Profile - It's a nice day for a white wagon!

Postby MadmanSean » Tue Jan 17, 2017 7:07 am

Ironing out these little kinks are going to make it one hell of beast when complete! Nice work!
Subaru ECU Unbricking, Unlocking and Bench Flashing/Recovery service! Check out SICK CHIPS @ https://www.facebook.com/SickChips/
http://forum.liberty.asn.au/viewtopic.php?f=56&t=35489

Garage:
2007 Subaru Liberty GT SpecB wagon - RIP
Cosmic Racing Coilovers | Kobe 340 Pump | AVO 3" Inlet | ID1000 | DBA T2 Discs | MU NS400 Pads | Invidia DP | Tomei FPR | Tuspeed BCS | GTX3071 | TGV Delete | W2A Intercooled | Catch Can | 20 Row Trans Cooler | Cusco Stuff | Whiteline Stuffs | Kido Tuned E85 | Empire 3" Exhaust |

1996 Hilux Surf SSRG
Non intercooled 1kz-te | Diesel | Auto | 2" Lift | 18psi MBCS | K&N Filter | 33" Muddies | 105RWkW and a shit tonne of Torque!
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Sat Apr 01, 2017 4:37 pm

Ok,
So
This happened: https://www.youtube.com/watch?v=DLHV8yA3zVw - huge smokeshow out the exhaust.

Dropped the headers and tested - no smoke https://www.youtube.com/watch?v=cDtjVhA4tU4

Removed the turbo and it has MASSIVE axial play: https://www.youtube.com/watch?v=u3SGAID3bks

Sent it back to mamba in taiwain, and they repaired it under warranty, because WTF.

Working on the dash waiting for the turbo to come back
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Power module for the dash system
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They fixed the turbo and sent it back express, which was much quicker than I thought! (2 days from taiwan!)
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Refitted the turbo and I somehow misplaced the straight ended oil feed line so I bought some AN4 line and fittings which is much nicer
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I also hit up yahoo auctions for a helical LSD front diff
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I've also picked up a plated diff center locally for my rear diff.

also managed to find a GFB Deceptor pro adjustable blow off valve for a reasonable price, just need to re-do the wiring.

The dash is going more custom - the tacho and speedo are also being driven by the arduino, and I'll adjust the speed by GPS. The main issue here is that the speedo would randomly start from 50km/hr, and the tacho is off as well - likely as a result of starting from the different point.

Still a bunch of work to do on the gauge system, family/personal situation is changing a bit at the moment, should have more time soon. Car should be mobile within a couple of weeks, and mostly "finished" (at least for current projects) in a few months.
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Re: Member Profile - It's a nice day for a white wagon!

Postby bigBADbenny » Sun Apr 02, 2017 12:33 pm

Love it! Who is installing the diffs and is the rear a 3.64 out of a my08+?
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