2zzge AE82 sedan conversion

[Hiro]

so wheres the shift light goin:P

Built into the tach, see the three LED's there? ;)

Where 11,12 and 13000rpm are on a Honda tacho :P

[CHA54]

sorted the T25 collector and fuel rail today. did some slight mods to the collector so it fits the T25 profile nicely, I didn't flatten the sides as I plan to port the turbo inlet flange to match the collector. Made up a 1/4" NPT bung to weld onto the fuel rail to convert it to return-style with a 90deg -6 full flow elbow. I'll make an alloy hardline to go from the return fitting to the fuel pressure regulator that will be mounted on the end of the head towards the firewall.

[CHA54]

Finished off the fuel rail with a -6 weld on fitting today, then cleaned up and sat the spare intake plenum in place, cleaned up the cam cover and proceeded to stuff up the application of VHT wrinkle paint :P

Nozzle blocked halfway through the first coat and then after removal and cleaning I managed to damage the seal in the top of the can and it ended up ****** paint everywhere and wasn't easy to get even thick coats onto the cover. I'm happy enough with how the red wrinkle looks so will strip the paint off, get another can and refinish it...

Plenum is just sitting in place at the moment, I still have to tap a 1/8" NPT hole in it somewhere for the intake air temp sensor.

[CHA54]

Got the rest of the return fuel system sorted this afternoon, mounted a turbosmart FPR800 on a custom bracket and bent up some 3/8 alloy hardline and flared it with some -6 AN tube fittings to connect the reg to rail.

[Branno]

This is looking really nice man. And it's even better that you are doing the work yourself! Good work. Keep it up. Think of the reward of seeing the finished product zooming around.

[CHA54]

de-honda'd the cam cover, took ages to strip the wrinkle paint from all the crevises... Also pressure tested the fuel rail and found a pinhole leak at the weld-on AN fitting so fixed that up and gave it a coat of satin black VHT.

Some pics from a few different angles showing clearances etc

[dutchie101]

Looks much better black - topped. Beautiful hardline work too. Coming together nicely.

[dwee.]

Looks much better black - topped. Beautiful hardline work too. Coming together nicely.

Agreed! Top looks better black! Very nice progress!!

[trdrolla1]

insane fabrication work love it!

Black is awesome

[MR22ZZ]

Looking good Jason.

A radiator, intercooler and fans will take up that nice big space out front pretty quickly.

[CHA54]

more stuff arrived, progress should be faster now.

Laser cutting order all done, got a heap of 2zz exhaust, T25 turbine inlet and exhaust, cluster bezel and 2jz flanges cut, also reveived another shipment from MWR with bosch 525cc injectors and a waterpump.

Edited August 8, 2011 by CHA54

[clifton]

your cluster looks so good! nice work :)

[CHA54]

More pics...

Bezel and Gauges sittiing in cluster face:

Bosch Combo 3bar Map/Intake Air Temp sensor and NGK AFX Wideband:

Turbo position in bay:

[Cee-Lo]

Turbo 2ZZGE, sounds like it's going to blow the doors off a lot of cars!

does the 2ZZ have stock internals or has it been replaced with more boost friendly items?

[CHA54]

stock internals.

[CHA54]

made a start on the manifold after work today, I've repositioned the turbo slightly to make installation easier and used a holesaw to recess the steampipe into the flange by 4mm which will make porting from oval to round neater.

Turbo flange is lined up to the center of the exhaust ports, so the manifold will end up as a symetrical ram-horn style:

[CHA54]

have got most of the turbo manifold sorted now, just a couple more welds to go then it's ready for facing, porting and coating.

[dutchie101]

Beautiful work again. Great to see such skill in motion.

[KIRIUS]

whoa.. amazing.

[CHA54]

Manifold's fully welded and ported now, got a couple of tight spots finished off by Craig at Extreme Custom Engineering in Archerfield as I couldn't get my standard tig torch in to weld it properly.... next purchase will be a weldcraft WP-50 micro torch :)

Also made a start on the radiator, using an AE101 china radiator custom-mounted with the inlet and outlet relocated. Undecided on what thermofans I'll be using but probably a set of WRX fans with integral shrouds. I've got the radiator mounted as far forward as possible.

[jeffy]

great progress... :] !

[CHA54]

modded the radiator today to suit the 2zz engine, machined up new 34mm inlet/outlets to weld onto the end tanks, chopped off the old ones, plated off the holes and welded the new ones in place:

Radiator hoses should be fairly easy using bits of chopped up silicone hose and alloy hardline in between:

[Branno]

And then I jizzed in my pants...

Great progress. Very interested in seeing a finished product!

[clifton]

I love your fab work!

[ben yip]

omg, another bullet