Abjerk's KA-T Build

This is for all those PICTURE THREADS ONLY. Motor installs, product writeups, showing off your car, put the thread in here.
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Abjerk
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Abjerk's KA-T Build

Post by Abjerk »

I've been lurking for quite some time now. I finally decided I should dive in and show what I'm working with. The body is a 1990 so technically this is a DE swap. It started out as somebody else's project. The car was completely gutted. I literally started with nothing. My goal is to turbo the car over winter and shoot for 400HP on E85. The current build list:

Block/Head/Transmission
1993 KA24DE
Wiseco 9:1 .020 Pistons
Eagle H-Rods
Clevite Bearings
ARP Main/Head Studs
Cometic Metal Head Gasket
PNP'd Intake/Exhaust Head
3 Angle Valve Job
EGR Block Off Plate
Spec Stage 3 Clutch
Fidanza Flywheel
Nismo Motor and Tranny Mounts

Cooling
Koyo Aluminum Radiator
ISIS Radiator Fan Shroud Kit
Mishimoto 68°C Thermostat

Exterior
Stock Chuki Aero
OEM 180SX Type X Wing
OEM 180SX Type X Kouki Lights

Fuel System
Z32 Fuel Filter
DeatschWerks DW300 320LPH Fuel Pump

Intake/Exhaust
Motoria S14 3" Exhaust (modified for S13 routing)
Nissan Q45/Z32 90mm Throttle Body

Coming home:
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Ricey body kit :/
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Holes? Come on...
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De-riceifying it
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6pt roll cage om nom
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This is what I had to work with.. not much
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A sign that it might live
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Before:
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I made the mistake of dumping those buckets... ugh
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Before:
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After:
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After:
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After:
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After:
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After:
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After:
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P&P + 3 Angle Valve Job goodness:
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Shiny!
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Cometic gasket + ARP studs
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Coming together:
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Stock cams for now:
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Adding the outer components:
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Finishing the timing:
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Side view:
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Mockup with valve cover:
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Latest progress as of 9/23/12
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Last edited by Abjerk on Thu Sep 27, 2012 11:22 am, edited 3 times in total.
klh6686
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Post by klh6686 »

Looks like it will be a solid build, what turbo do you have in mind?
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Abjerk
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Post by Abjerk »

I hope so. My number one attention to detail was making the engine damn near bulletproof so all the reliability mods were essential to the build. As for turbo, I was thinking of going with a Precision 5858 .82 A/r T3 Journal bearing turbo.
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Abjerk
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Post by Abjerk »

Bump: Pics are up! Sorry for the cell phone quality. :D
klh6686
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Post by klh6686 »

Not very familiar with that turbo, what kind of power are you expecting?
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Post by sdaigle240 »

you could EASILY make 400whp on an hy35 e85 that costs under 300$. people make damn near 400 on 20psi 93 octane. figured id make mention, i also see 18psi before 3500 rpms, and the thing eats up ferrraris, GTRs and AMGs on the highway :)
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hy35 18psi Build Thread: viewtopic.php?t=38784
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Abjerk
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Post by Abjerk »

I'm not too familiar with Holsets. I know OF them but nothing about running them. I always kind of assumed they were truck turbos from Cummins. I know the HX35 is pretty popular around these parts though. 93 or E85 is the plan. I'd love to stick to E85 though since its pretty common around here to the point I could get away with it. My buddy is a parts dealer so I can get a good deal on the Precision turbo which is why it was my choice.

Off topic: my tranny is junk. I plan on buying an S14 tranny Monday to mate to the S13. Both are 5MTs so they should be ok. No driveshaft swap necessary. Anyone familiar with that sort of setup?
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Post by supakat »

You will be fine. All you need to do is knock off the dust cover on the s14 tranny. Don't worry about the crank sensor that is on the tranny as well,
12.96 @ 116.36 - 2.1 60ft - 11/2011
13.1 @ 114 - 2.3 60ft - 8/2012
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Abjerk
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Post by Abjerk »

supakat wrote:You will be fine. All you need to do is knock off the dust cover on the s14 tranny. Don't worry about the crank sensor that is on the tranny as well,
I should still be able to get away with using my S13 94+ flywheel dust cover right? Also, the crank sensor on the S14 isn't necessary since the S13 never had one correct?
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Post by supakat »

Yes and yes.
12.96 @ 116.36 - 2.1 60ft - 11/2011
13.1 @ 114 - 2.3 60ft - 8/2012
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Post by Abjerk »

Ran into a snag with the S13 5speed MT:
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So I picked up an S14 5speed MT (MUCH better):
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Got the clutch and flywheel installed:
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Mating the tranny to the long block:
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Finally we got it dropped in:
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However, at this point the clutch fork doesn't move.. its not engaging the throwout bearing for some reason so we will need to pull it back out and inspect it again. Joy... :roll:
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Post by Abjerk »

Well we got everything back in. The throwout bearing wasn't pushed down hard enough on the assembly and I guess wasn't pushed back far enough on the spline.

However, it is STILL extremely difficult to move the clutch fork. We need to use a pry bar in order to move it. I know its a Spec Stage 3 clutch but is this normal? :?
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sdaigle240
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Post by sdaigle240 »

oh yeah, good luck moving the clutch fork. thats why hydraulics are used! im assuming the motor is just on a stand and not in the car, so no pedal.
airman wrote:I'm all about spreadsheets. Bitches love spreadsheets.
schmauster920 wrote:I shall cast my own pistons in the sands of time, then forge them in the depths of hell.. as funds allow
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hy35 18psi Build Thread: viewtopic.php?t=38784
RIP MJL best friend of 20 years and the man who showed me 240s
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Post by supakat »

Be careful not to knock the fork off the TOB or pivot ball.
12.96 @ 116.36 - 2.1 60ft - 11/2011
13.1 @ 114 - 2.3 60ft - 8/2012
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Post by Abjerk »

Thank god for hydraulics then! :D Yeah it was just sitting in the stand when we were attempting to move it but now its sitting in the bay again. All should be well once we hook up the hydraulics. Now all that is left to do is hook up lines and electrical and hopefully we get a pulse! :D
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Post by Jonas »

ahhh nice pics. remind me of my set up
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89 caged race car
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Post by FlatBlack »

Coming along nicely!
89 240SX Coupe
02 GMC Sierra Z71 5.3L 4x4
03 Kawasaki 636 ZX-6R
77 Honda Trail 70 140cc swap
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Post by Abjerk »

Slight change of plans on the turbo build due to some things happening in my personal life. The turbo build is now very budget oriented. However, I was just able to pickup a top mount T3/T4 SSAutochrome turbo manifold on the cheap. I know its not the BEST manifold but the welds look decent and I don't see any globs of weld that could possibly break off. Also, I will need to either CNC cut a block off plate for the external waste gate flange or hack it off and weld over it because.... I am finalizing a deal to buy a rebuilt HX35 for $250! :D
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Post by sdaigle240 »

damn, well atleast your not pulling the plug!

be careful with that manifold! not for quality but for fitment! id be pretty surprised if an hx on that mani clears the BMC
airman wrote:I'm all about spreadsheets. Bitches love spreadsheets.
schmauster920 wrote:I shall cast my own pistons in the sands of time, then forge them in the depths of hell.. as funds allow
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hy35 18psi Build Thread: viewtopic.php?t=38784
RIP MJL best friend of 20 years and the man who showed me 240s
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Post by 91white_ka »

You still need an external wastegate with the holset. The internal gate port is not large enough to bleed enough pressure on a gas powered engine.
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sdaigle240
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Post by sdaigle240 »

where do you guys come up with this stuff!?!? thats a silly comment. the port size is no different than any name brand internally gated turbo and would work perfectly fine. the main issue is you cant clock the turbo as needed with the internal gate and the pressure is high.
airman wrote:I'm all about spreadsheets. Bitches love spreadsheets.
schmauster920 wrote:I shall cast my own pistons in the sands of time, then forge them in the depths of hell.. as funds allow
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hy35 18psi Build Thread: viewtopic.php?t=38784
RIP MJL best friend of 20 years and the man who showed me 240s
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Post by Abjerk »

Well I hope I have clearance. That manifold was a steal but I'd hate for it to be a waste of money if it doesn't. I might be able to have a fab shop do some magic on it if that is the case.
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sdaigle240
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Post by sdaigle240 »

look up search terms like "top mount" and "clearence" issues. get an idea for what turbos are not fitting and then look at that MASSIVE hx housing.
airman wrote:I'm all about spreadsheets. Bitches love spreadsheets.
schmauster920 wrote:I shall cast my own pistons in the sands of time, then forge them in the depths of hell.. as funds allow
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hy35 18psi Build Thread: viewtopic.php?t=38784
RIP MJL best friend of 20 years and the man who showed me 240s
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Post by Abjerk »

I noticed. :( Hopefully I don't have any issues or I might need to invest in a log style it looks like.
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Post by FlatBlack »

Abjerk wrote:I noticed. :( Hopefully I don't have any issues or I might need to invest in a log style it looks like.
I kind of like this solution 8)

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Post by supakat »

HX35 and that mani will not clear the BMC if using the stock housing which I assume since the BEP is $200 alone. You can buy the cheap cast treadstone knock off for $90 and it will work. That is what I am using now. I will be changing out to the new CX mani which places the turbo in front of the motor. Good luck.
12.96 @ 116.36 - 2.1 60ft - 11/2011
13.1 @ 114 - 2.3 60ft - 8/2012
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Post by Abjerk »

supakat wrote:HX35 and that mani will not clear the BMC if using the stock housing which I assume since the BEP is $200 alone. You can buy the cheap cast treadstone knock off for $90 and it will work. That is what I am using now. I will be changing out to the new CX mani which places the turbo in front of the motor. Good luck.
I was hoping to hear you chime in on this! Your build has been one huge inspiration to me. Your build definitely reflects your efforts. So I have to give you props for you and your contributions here. I will look into those manifolds. In the mean time I need to sell this one I have now.
Last edited by Abjerk on Wed Oct 24, 2012 8:57 am, edited 1 time in total.
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Post by supakat »

Thanks man. It is pretty cool for people to say that. We have several other threads like sdaigles, schmauster, and some others who are backyard DIY'ers with good results.

Towards the bottom of this link, you will see how the housing hits with old mani.

viewtopic.php?t=49585&postdays=0&postor ... &start=500

This one shows how I ported the mani. You also need to weld shut the 3 t4 mounting holes. Some pics were moved from FB so they are dead. Will try to find them for you.

viewtopic.php?t=49585&postdays=0&postor ... &start=520
12.96 @ 116.36 - 2.1 60ft - 11/2011
13.1 @ 114 - 2.3 60ft - 8/2012
KA24DE-T
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Abjerk
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Post by Abjerk »

supakat wrote:Thanks man. It is pretty cool for people to say that. We have several other threads like sdaigles, schmauster, and some others who are backyard DIY'ers with good results.

Towards the bottom of this link, you will see how the housing hits with old mani.

viewtopic.php?t=49585&postdays=0&postor ... &start=500

This one shows how I ported the mani. You also need to weld shut the 3 t4 mounting holes. Some pics were moved from FB so they are dead. Will try to find them for you.

viewtopic.php?t=49585&postdays=0&postor ... &start=520
Interesting. Is this the knockoff you are referring to? I notice that the flange is rotated so as to avoid the BMC which is awesome!

http://www.speedyracer.com/exhaust-part ... o-Manifold

In total, all I'll need to do is just weld the T4 holes shut and maybe port the manifold holes a little bit. Seems really easy and straight forward for such a cheap manifold! :D

I've also noticed in some other build threads that people have a custom downpipe they've made. Is this necessary due to the HX35 being rotated away from the BMC? Or can I get away with purchasing a pre-made DP?
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Post by supakat »

Yes, same mani. As for DP, it will have to be custom because no one makes off the shelve kits for the holset 5 bolt or v band.
12.96 @ 116.36 - 2.1 60ft - 11/2011
13.1 @ 114 - 2.3 60ft - 8/2012
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