AK_Slick's KA-T Coupe (Big Update April 18, 2010)

This is for all those PICTURE THREADS ONLY. Motor installs, product writeups, showing off your car, put the thread in here.
ak_slick
Knows Some Stuff About 240's!
Posts: 216
Joined: Fri Dec 01, 2006 8:19 pm
Location: Las Vegas,NV

AK_Slick's KA-T Coupe (Big Update April 18, 2010)

Post by ak_slick »

First off... apologies for taking so long to post my build on here and sorry for the huge dump of pictures on one page. I will be trying to keep it up to date from now on for you guys.

Alright gentlemen. I have been meaning to have my build thread for my car on this forum as well as my local car community/drift forums. So here it is. I am going to update this as frequently as I can to hopefully give back some from my experience and sometimes painful gleanings/mistakes.

The always up to date thread is in my signature on Vegasdrift.com since that is where I am trying to do well in the VegasProAm Drift Competition this year.

Here we go there will be a lot of pictures feel free to ask questions and I will respond as soon as I can.

Friends finally convinced me to put up a build thread. Go to the most recent post for current progress. It will take me a while to update all the history in the earlier posts.

Basically, I tend to be a function over fashion kind of guy. I like things to work and work well. Don't care so much how they look although I might get around to making a car look decent one day. Feel free to ask me about anything I have done. Hope you enjoy my build as I update it.

Current Mod/Part List as of Feb 25 2010

Body
BMagic Side skirts
BMagic Rear Bumper
Front Bash Bar
OEM Front Bumper
Carbon Fiber Hood

Suspension/Drivetrain
GR+ Pro Coilovers with z32 rear lowers (8k/6k)
Urethane Motor Mounts
Stock Transmission mount filled with 40 Durometer Urethane
5-Lug all around
Z32 Brakes 26mm Fronts (all aluminum)
Z32 17/16" Brake Master Cylinder
Old Sentra Brake Booster (Nice and low profile)
CNC Hydro E-brake
Z32 Cable E-Brake (for parking)
Z32 Aluminum Uprights in the rear
Ebay Godspeed Adjustable links
Z32 Transmission with RB26 AWD Bell housing
Chromoly sway bars
Ebay Tension arms
Nismo Power Brace
Aluminum Steering Bushing (machined by me)
Energy Suspension Z32 Subframe bushings
1-piece lightweight steel drive shaft
Kaaz Limited Slip Differential
All eccentric alignment bolts in the rear subframe welded so they do not move since all adjustment is now made with the adjustable links
Circuit Sports inner and outer Tie Rods
ARE Rebuilt Steering Rack

Motor Mechanical
Short Runner Turbo manifold (made by me)
AMS GT3271 Polished Compressor, Precision .63 AR exhaust side, .50 Compressor
Midmount Intercooler
Custom Fabbed intercooler piping (homemade)
Fabbed 3" Exhaust (homemade)
Tial 50mm BOV (new style)
Tial MV-S Wastegate (38mm)
Aeroturbine Resonator
2.5"-3" down pipe (homemade)
Modified Ebay fuel rail
S14 KA
S13 intake manifold, gutted of butterfly valves, and everything else
Nismo Thermostat
Koyo Radiator
Nissan Quest 110Amp Alternator
Modified SR20 Aluminum Pulleys to work with KA
12lb RB20 Chromoly Flywheel
Z33 (350z) F1 Racing 6 Puck Clutch
Clutch Fan Removed
Derale/Bosch 4000cfm fans, custom shroud


Engine Mangement
Megasquirt II with Boost and Launch Control
RC Engineering 1000cc injectors (E85)
Walbro 255lph Fuel Pump
Greddy Fuel Pressure Regulator
GM Wasted Spark Coil Packs (40,000V?)
Distributor Replaced with a custom Camshaft Position Sensor (made by me)
GM Idle Air Control Valve (removed the 3 Nissan Valves... too many valves)
2 Bar MAP Sensor
Boost controlled by a GM Boost Solenoid
Last edited by ak_slick on Sun Apr 18, 2010 12:01 pm, edited 8 times in total.
ak_slick
Knows Some Stuff About 240's!
Posts: 216
Joined: Fri Dec 01, 2006 8:19 pm
Location: Las Vegas,NV

Post by ak_slick »

This is when I first bought my car. It had a poorly running rb20det with nothing but problems. Pretty much all of them incurred due to being owned by someone who didn't know how to care for it properly. The rb20 was short lived for me due to once I did get it running well, the timing belt idler pulley bolt vibrated loose in the driveway and things didn't go well. So I moved on to a KA since I had an extra laying around.
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Interior when I first got it.
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It was a nasty engine bay before... well it is still pretty rough.
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Better
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RB Out
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All the chassis wiring was stripped and redone The nasty beginning
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KA was disassembled all clearances inspected and everything was perfect. Here it is getting finished up.
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How the oil line was run on the KA
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RC Injectors installed 1000cc, new wires
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The beginning of the Megasquirt II before all the mods.
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Some parts I got really cheap... the Overflow window eventually fell out... big surprise... I will have to make my own one day. Tiny T3 .50 trim
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Basic ECU functions being tested (we couldn't test the experimental functions)
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I machined a block to adapt a GM IACV to mount where the main Nissan one used to live on the back of the stock manifold plenum
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Nissan Quest 110Amp Alternator Modified to fit KA.
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Welded in a turbo return oil bung to the Oil Pan
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A z32 came into the junkyard while I was there and I pillaged it for all it was worth and all my little car could carry. I managed to take the seats as well as the entire braking system, rear 5 lung, and aluminum uprights.

So I worked some magic to make the seats fit.
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Last edited by ak_slick on Thu Mar 18, 2010 11:04 am, edited 2 times in total.
ak_slick
Knows Some Stuff About 240's!
Posts: 216
Joined: Fri Dec 01, 2006 8:19 pm
Location: Las Vegas,NV

Post by ak_slick »

Some pics of the old JGS log manifold I was running previously. It is a little close to the brake master for my taste... I ended up melting a reservoir. I will have to see if I have the picture of that somewhere.
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The JGS didn't have a nice v-band for my Tial Mv-S so I added one myself... It tucked up quite nicely I think. This manifold was sold to someone on ka-t last month.
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Here is my dash... more or less. Looks like crap, but the gages are perfect and right where I like them.
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Some Cheap Buckets I picked up. They were bolt in after I fabricated some mounts
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Here is the Camshaft position sensor optical wheel from a 4g63 and on the right is the one I made, it is a 24-1 with a 2 slit on the inside ring. Below is the distributor modified to take the wheel.
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I got a china manifold given to me due to not fitting anything and I cut it up and kept the flanges... I am sure I will use these later.
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Old picture of the Passenger side engine bay... Nice ebay FPR worked well for 3 years, then finally crapped out. It wore a hole in the pressure baffle. It has been since been replaced by a Greddy one.
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ak_slick
Knows Some Stuff About 240's!
Posts: 216
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Location: Las Vegas,NV

Post by ak_slick »

So I have been busy this last week. Making a quick manifold, new down pipe, changed out the differential to a Kaaz, Rerouted the power steering lines, Notched the tops of the strut towers so the camber can now be adjusted to the fullest that my coils allow for... etc. Here are the pics.

Starting the Manifold (This was a really quick one btw so please forgive my welds)
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And Tada! Finished! Just like that.
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Hydro e-brake hooked up and bled.
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Trimmed the strut tower for the camber plate adjustment.
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Rerouted the power steering lines
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The cars current status as of Jan 14 2010. There is a lot more clearance with this manifold compared to all the others I have run on my KA. Not to mention this one actually works and fits.
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ak_slick
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Post by ak_slick »

The race to prep for the event. A little unsure if I will make it but I am being optimistic still at this point in time.

Quick Update on today's progress.

All lines hooked up.
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Down Pipe Finished
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Battery Upgraded and relocated to the Trunk... have to make a tie down still.
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Kyle Made a Heat shield for me.
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One of my slave crew installing the shield. (Big thanks to Devin pictured here as a speedy gnome)
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Kyle Making a coolant Overflow Tank... this guy is a machine
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ak_slick
Knows Some Stuff About 240's!
Posts: 216
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Location: Las Vegas,NV

Post by ak_slick »

Hydro E-Brake Anti-Trans-Tunnel-Flex Mount :D

1/8" Steel From Sheet Bent by my large mexican laborer/friend... Big thanks to Jordan... He used a clamp and his hands. It was ridiculous.
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Mocked Up
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Tapped and mounted. My Tunnel used to flex down an inch when the e-brake was tugged... now the e-brake handle bar bends before the tunnel shows any signs of flexing.
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Busy week with school... More updates soon.
ak_slick
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Location: Las Vegas,NV

Post by ak_slick »

Made some progress... big update should be coming late tomorrow.
Adjusted the steering shaft
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Still have to clean up the messy wiring
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Don't know what is happening here yet. You can figure it out. :D
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ak_slick
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Location: Las Vegas,NV

Post by ak_slick »

Alright... here we go!  My idea of a nice clearance cage! Happiness for me.

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One Box in. Low profile :D Saves the ankles
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Door Magic
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Yay
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Good Look at the current state
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They are straight I promise
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Working window :D Yes!
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From Driver view
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Nascar Bar ftw.
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Windshield Bar sits way high
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ak_slick
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Post by ak_slick »

And later we decide to go shrek green on the cage. Nasty but it will clean up.

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More Painting

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ak_slick
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Post by ak_slick »

Some Pics of the Current state before priming and spraying the exterior.

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more
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ak_slick
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Post by ak_slick »

Now my car has been BLUED!
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A few runs but I am VERY HAPPY with it. :D
ak_slick
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Post by ak_slick »

So today I decided to reposition the seat more to my liking starting by removing the stupid mount bar that force the front to be so high.
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So seat Before
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And After Also put the rear quarter glass back in after cleaning it
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Fixed the faulty camshaft position sensor connector (Big thanks to Josh and Kyle) The terminals were soldered directly to the wires and then the connector was filled.
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And little thing but we pinned the trunk lid
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ak_slick
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Post by ak_slick »

Anyway it is going to get run in very mismatched form this next event as I am not taking the time to paint the bumpers and side skirts till after the event.

Chopped the "battle dash" up to make it fit. For those of you who don't know the gage placement is tops, but the looks are pretty rough.
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Got the side skirts and rear bumper back on, as well as reinstalled the battery redid a few wires. Kyle is working on wiring up the ignition and Buckey is lending a hand.
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ak_slick
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Location: Las Vegas,NV

Post by ak_slick »

Got the car back down on the ground.
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Got the ignition and some more gages in.
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Got it running happy again!
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Spent forever working on getting the damn tint off the passenger quarter glass...
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Started laying out some stickers
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And deposited other stickers.
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ak_slick
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Post by ak_slick »

My friends company... Proud to run his name on my car.
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Measured for overfenders...
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Took it out for an alignment
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Things were messed up. Forgot to take an after picture but things are much better now.
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An Important Sticker added.
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ak_slick
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Post by ak_slick »

Dyno Sheet (Corrected numbers at the bottom)
335hp/386tq at 1 bar (14.7-16psi)
Stock 232 Cams
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Just wanted to let you all know that it is official. I am insane.

Ridiculous amounts of mods to come. Just ordered A LOT of parts.

Scheduled for this month...
-Z32 trans with Rb26 bell housing on a KA
-Rb20 Flywheel with a Z33 Clutch
-Custom Drive shaft
-Power Steering Cooler (I started boiling the fluid at the last event)
-Oil Cooler
-Front Bumper (yay)
- and potentially more... but I don't want to promise too much yet.

A shot from the last event courtesy of Chris W.
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ak_slick
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Post by ak_slick »

got a lot of parts in order to take a pre-emptive upgrade/cooling strike and make my car fully legal and safe for competitions I went a little overboard but I am not done yet... before someone asks... the parts were not overnighted and are not from Japan but they came really quick anyway. Here is what has arrived so far.

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Quick Summary:
Fire Extinguisher, SFI Padding, 5 pt harnesses, fire suit, underwear, gloves, shoes, rb20 lightweight flywheel, 350z clutch, accusump and manual valve, battery cut off switch, power steering cooler, and SPL endlinks. :D

Time to start the bolt-on phase.
ak_slick
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Post by ak_slick »

So I am officially beginning Rev. 2 of my project.

Here is the progress from tonight. Lots should be happening tomorrow.

Pulled out the RB26 AWD transmission.... The Beast.
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Separated the Bellhousing
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Bolted up a KA plate And began drilling out the holes that didn't match. Note how a bunch of them are right on this is before any drilling.
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Big thanks to Chris for the rb26/z32 trans info... it is saving me bank over the Mazworks kit. Also thanks to THEDRIZZLE (Craig) the extra muscle was very welcome with the chuck of metal. More to come tomorrow.
ak_slick
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Post by ak_slick »

Alright... So managed to get the harnesses installed, the fire extinguisher mounted, SFI Roll cage padding attached, and the motor 99% prepped for pulling tomorrow. Here are the pics.

Harnesses SFI 16.1 Approved yay
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Fire Extinguisher
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The roll Cage Padding cleared the window crank... I had about an extra inch but I got lucky since I did not even think about the padding when I put the crank there.
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Got some Tien Inner Tie Rods to go with the SPL Ends :D
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And how she sits at the moment. More to come Tomorrow.
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ak_slick
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Post by ak_slick »

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Onto Progress and Challenges yay!
Motor Out
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This is what I believe an Entire Engine Harness should look like... trying to get it down to less plugs but I will live with 3.
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4000 cfm Derale/Bosch fans came in with the shroud.  I just need to modify it a bit.
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Separated the Trans.
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Old Ka24de F1 Racing 6-Puck Clutch on top of 350z clutch. The 350z is bigger which is better in this case( holds more torque) Note the bits of material missing in the pucks... This is bad.. but I cannot complain for the price and is normal for high abuse drivinmg. I would recommend people be aware of the way these clutches wear before buying them. THe pressure plate on the other hand seems just as strong as it was the day I put it in a year ago.
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Heat spots from hard driving and irregular clutch wear
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Onto the Rb26 Bell housing to Ka block. The top 3 were the ONLY bolts that I drilled. Everything else lined up except for one that I decided not to drill. It was pretty unbelievable.
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And here is the bell housing on the block.
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Which brings me to a detail I missed... the Clutch Slave cylinder is different. If anyone has a push style that will work with this let me know. I ordered one already but if I can get one sooner than tuesday or machine something I will.
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And the work continues.
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redline240sx
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Post by redline240sx »

Nice build man, u guys did a great painting job on the car.
S13 KA-t
ak_slick
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Post by ak_slick »

Alright... so since I wasn't going to pop the z32 bell housing by myself since I have a tendancy to loose the springs and bearings I decided to work on modifying the fan shroud to get a properly ducted 4,000cfm of cooling fury. Sadly I need a thin strip of sheet metal to weld in the middle but after that add a little weather stripping and the mount tabs and it is cherry.

How they came
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Approximate locations after trimming
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After tacking everything back up... minus the middle piece.
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Will get this finished tomorrow.
ak_slick
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Post by ak_slick »

Alright... sorry about the late update... had a couple beers at Crown and Anchor last night... oh so good.

Anyway here is my bang up fan shroud all finished. Used some trunk weather stripping to seal/cushion between it and the radiator. Sealed off the little holes in the side with some aluminum tape and painted it some Satin Black that was laying around the garage.

Primed
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It's a little close to the top radiator hose but it still fits on with a clamp. I know the welds look nasty but I was too lazy to grind off the powder coating. So I just let it melt off as I was welding.
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Working on the z-trans at the moment so expect more pictures later.
ak_slick
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Post by ak_slick »

So messed with the trans a little bit this morning and found a couple things... like my camera!
Anyway: First the trans looks beastly. Second the wrong plate is on the trans sadly and will be switched out today as you can see in the first picture. The clutch throw out fork needs to be mounted in the upper location which isn't tapped on the plate we put in there which I believe is the rb26 plate.
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In another note: The starter holes line but the rb26 bell is not a bolt through starter; it is a bolt to starter  holes (the holes are threaded) so I drilled out the holes in my starter and it bolts right up. I will take a picture later.

I just thought I would show how I hooked up my GM IACV, and where the coil packs got cleverly mounted on the back of the intake manifold since it was just hanging there at eye level. Off to school/work again.
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Today's continuing Saga.

So the front cover on the transmission with the clutch fork pivot ball was the rb26 one... and it needed to be the z32 one due to the pivot ball being located in the wrong spot. So first thing I swapped that plate... Then I chased the threads on some bolts holes that were a little off.
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After that we sourced a Slave cylinder... which I think is actually from an Accord. Anyway it is pretty close to the rb26 bolt pattern but still required to have the holes drilled out a little bit larger and then some washers to space it up from the bell to align the plunger with the fork properly.
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Next was the 12lb chromoly rb20det flywheel.
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And then the 350z clutch 6 puck which is 1" larger in diameter than the KA clutch
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Next bolted up the frankenstien transmission
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All the bolts line up GREAT!
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The rb style starter apparently bolts opposite the KA style but with the exact same mounting locations so I drilled out the starter threads so the bolts would enter through the other side and fasten to the trans.
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and voila
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ak_slick
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Post by ak_slick »

Today ended up being a lot more driving around getting stuff rather than working on the car but here is what I accomplished.

So got the motor and trans dropped into the car. Next came the drive shaft.
The one piece was my 240sx shaft and the two piece is the one from the z32.
I went by Dan's Driveline and had them start making me a brand new one to the correct length. It will be ready on Monday.
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I noticed that the shifter is a little farther back... which was expected after seeing Josh Guild's setup. It is also a little off center. I am debating shortening the linkage an inch so it will sit closer to the normal location. More to come on that.
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Started fabricating the transmission mount bar. I cut some steel to the approximate good lengths. The welding comes tomorrow.
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I love Do-All Saws.

So while I was working on things I found that my steering shaft input spacer was loose. So I fixed the steering spacer bolts loosening.
From this
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To Weldement.. I actually welded all the nuts on the bolts and the opposites to their respective opposite housings.
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Took a look at where the z trans mount ended up being with the regular 240sx mount bracket. It was surprisingly close and I debated just making two plates to give the bracket all 4 mount points
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Then I used it to jig my mount.
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Welding after tacking under the car.
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Some quick welds on dirty metal... the metal in the middle was impossible to get anything close to clean due to having some crazy dirt and paint embedded in it.
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Painted Satin Black
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Bracket all Bolted up
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Perfect ground clearance... Now I just need to make my exhaust a little tighter to the chassis.
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Test painted a Rim to see if I want to go ahead with all of them. I think it looks pretty good. I am too broke for powder coating right now so Paint is going to be it for a while.
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Tomorrow's Project the shifter linkage... it sits a little far back right now.
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ak_slick
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Post by ak_slick »

Sorry for the late update... lost track of time.

Worked out the shifter today. Originally I was set on shortening the linkages and making a custom bracket but then upon further observation decided it wouldn't require much notching to make the z bracket fit.

After drilling it out.
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Found some metal to make a bracket for the bolt to clamp on.
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Test fit after trimming
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My Good friend Jordan drilling out the bracket... he looks smallish from this angle.
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All installed... I ran out of white paint.
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The drive shaft got finished up by Dan's Driveline. They did an amazing job. Fits Perfectly and with all rebuild-able u-joints.
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Pat stopped by to bring me a seat that is certified to not spontaneously combust.
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ak_slick
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Post by ak_slick »

Started out the evening wanting to make my car easier to jack up... Having seen a similar thing on a car at FD I went to my local pile of metal remnants and salvaged some useful material.
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Ended up going with the green to make it easy to spot under the bumper
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How it sits... just low enough to spot easily if you are looking for it, not too low that it scrapes on everything.
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Got the seat in... turns out it would mount to my old rails perfectly if I just flipped one around. Forgot to take a picture of the flipped rail. I will tomorrow.
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Cody Volunteered to paint my rims... and I know powder coating looks soo much better but it is also soo much more expensive. Around $50 a rim when I have spent $10 on paint for all 8 rims so far and no one notices the chips when they are spinning.
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ak_slick
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Post by ak_slick »

Buckey helped me bled the honda slave cylinder... man this is one very stock feeling clutch the honda slave is larger diameter which gives it a great feel with the upgraded pressure plate. Also the old braided clutch line looks like it was made to be there.
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Started to mock up and mount all of the oil system. The is an oil filter on the frame rail, oil cooler in front of the passenger wheel well, and the accusump is nicely tucked away in the nismo power brace below the fans. Measuring for the lines and figuring out what fittings I need.
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Oil Cooler
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Accusump
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Time for bed. Here is tonights progress.
Fixed my front sway bar brackets... replaced them with Energy Suspension... Much better.
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Figured out what pieces were needed to solve to plumbing nightmare. Here is the magic combination (almost)
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Where it goes...
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Accusump Mounted... made a bracket for it to strap onto underneath
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It was impossible to get a good picture of this... maybe I am too tired but this is a picture of where the genius plumbing goes.
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Shot of the valve Bracket
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got the Pull switch for the valve mounted
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Got the Battery Cut off mounted.
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Some AN Stuff
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I started to work on the Oil Block adapter but got kicked out of the garage so it will come tomorrow.

And now everything is up to date... sorry about the huge dump of pictures and info but I hope it will help people out.
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Post by Turbo24sxt »

wow man good looking setup ...
Anthony
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TanManS14
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Post by TanManS14 »

Awesome build. You have some insanely badass tools/ must know people with badass tools. Koo-dos for diy man, great thread. Made really great power and an awesome torque for that boost. Also actually like the manifold too, real nice downpipe routing.
- Why did you got with wasted spark in particular? Just curious.
-Do you find 12x 12 maps to be plenty sufficient?
-Did someone cnc that trigger wheel for you?
It's always broken.
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