The Zenki KA-T build thread!

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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Re: My '95 zenki build thread!

Post by shift_down » Thu Apr 24, 2014 8:53 pm

Looks real good, keep it up!
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My build thread: viewtopic.php?t=57539

TrackStarGT
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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat May 03, 2014 3:51 pm

Did quite a bit of work yesterday, got the engine bay cleaned up, the subframe cleaned and reinstalled as well as the steering rack. engine bay is ready to receive its refreshed power plant.

Ended up having to deck the block which means more money and time. going with a cosworth head gasket and a new timing cover which Im waiting on so it can be decked with the block. I love the fact that my machinist has done KAs before and knew to tell me to bring my timing covers to him, we KA guys know this well but not all machinists know.

Anyway, cant wait for better more exciting updates: like motor built and going in! Better turbo! Transmission swap, clutch upgrade, etc...
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
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My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by shift_down » Sat May 03, 2014 4:05 pm

Awesome! I need to find a guy in mybarea that works on KAs too. Remember to center the steering rack as well.
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Re: My '95 zenki build thread!

Post by AFKOUKI » Sat May 03, 2014 4:58 pm

Great progress man!
Its weird I was thinking earlier how my valve cover would look in wrinkle red, and you did it to yours. Looks great!

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat May 03, 2014 5:15 pm

Some pics..
ImageImageImageImageImage
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat May 03, 2014 5:31 pm

I dug up an old thread and ran across these coils. I really like them because they're aesthetically badass! Nice price too! Anybody have any objections to running them? They seemed to work for that guy, but we all know the true test is time. I haven't found much else about them, so if anybody has got some valuable knowledge please enlighten me, thanks! Image
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sun May 11, 2014 10:16 am

No input on coils eh? Well block should be done any day now, which when it is, it will be built ASAP and dropped in the car. I guess I will be a guinea pig for the community, I will be running an evergreen timing set. I know the risk I run, and im willing to take. So stand by as I put miles and plenty of horseys through it. On another note, one of the Clevite 77P rod bearings that I ordered came damaged. looked like tooling marks on the bearing surface. I think it is safe to assume that it is unusable and am sending it back. Here are some more pics.

ImageImageImage
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by tacokiller07 » Thu May 15, 2014 5:56 pm

Nice build thread!! I, kinda wanting to see the final built engine running! Seeing how you said mega squirt was easy to install and getting familiar with it I might go the same route!

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat May 17, 2014 7:24 pm

Thanks much for the props on my build, I really appreciate comments like that.

That makes two of us at least lol, I cant wait to get this motor together and running like a beast. Right now the only thing holding me back from making 400 ponies are my injectors. I have some 550s in now that i could get maybe 650cc out of but really need to go bigger. Im looking at some 1600-2000cc injectors and a flex fuel sensor. I have one station that sells e85 and its in knoxville about 50 miles from me, the sensor would allow me to run 93 until I could get the e85. Another great feature of the MS ECU. And anything that can let me put AUDI R8 coils on motor must be badass and worth it..lol
Image

Image
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by street_240sx » Mon May 19, 2014 6:39 pm

I wouldnt use vw coils, known for going out alot. I replaced my coworkers mk6 with r8 coil packs. Just run chevy coils. What turbo manifold is that?
03 evo8 gsr: stroker 2.3 ;)

04 evo8 gsr: totalled

96 integra gsr: sold

89 s13 coupe: stock dohc, gt3076, megasquirt

started 3/15/08, running 1/18/09, finally turbo 2/9/14 lmfao

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Re: My '95 zenki build thread!

Post by TrackStarGT » Tue May 20, 2014 1:14 pm

well unfortunately its too late, got six of em on the way, two for back up. It is an OBX off of ebay, seems to be pretty good all around material and fab wise, fitment however, I had to take to my fab guy to have it tweeked. http://www.ebay.com/itm/OBX-Turbo-Manif ... a1&vxp=mtr
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Fri May 23, 2014 6:15 pm

Got lots of work done last night and today. Last night tore down the whole engine to plasti-gauge it. It clearanced perfectly on all five journals, which was a sigh of relief. Also checked the thrust bearing clearance, it was as tight as it could be within spec. .002 on each side. So, bottom should be good to go, i hope! Got it back together and put in the car, took an hour and a half with me my friend ryan and one gigantic engine hoist, lol.

ImageImageImageImageImageImageImage
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

TrackStarGT
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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat May 24, 2014 8:43 pm

Well I have a very irritating, yet funny story. I have the whole car almost completely back together, Im pretty much adding fluids at this point. So I filled the motor with oil and go to pull the dip stick and.......................no dip stick! OH $#i+ i said! lol. now I have to pull the whole exhaust side, turbo and manifold, which will take a freaking hour. I should have it running, or attempting to run, tomorrow.
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sun May 25, 2014 4:31 pm

Got the dip stick in lol, got everything back together, all fluids in battery in, turn on ignition and my 90* fuel fittings both started spraying fuel, couldn't get them to stop so ordered new fittings with barbs instead of the swivel. Waiting on parts to start it up yaaaaaay! fail!! Well see what happens wed or Thursday.....
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Mon May 26, 2014 7:24 pm

Got home and immediately jumped on the car, for the time being I modified the 6AN 90s on the ends of the rail, cut the ends off leaving the bend part hanging there, I plugged those ends into the rubber braided hose and clamped with worm gears. It held long enough for me to stab the distributor about 5 different ways, and got it to come alive which I was stoked to hear. Ran it about 30 seconds and blew the fuel line off the modified fitting lol. So I stopped there to wait on my appropriate fittings to show up. Can't wait to fire this bad boy up and hear it boost and growl! Haha , soon my friends!
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Thu May 29, 2014 12:23 pm

Well its together and its boosted! Again! woohooo! I made it to the gas station which is .2 miles away lol. It died on me on the way back. It is not wanting to start when its at operating temp. Any common things come to mind KA-Ters?? I did get a couple runs in third and fourth and its pulling well, boost is only hitting 140 KPa, thats only about 6 psi. so that makes me happy with how hard it was pulling.
Image
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by adamky » Thu May 29, 2014 1:14 pm

So fresh and so clean clean.

One thing to look at for the starting issues is your CTS (coolant temp sensor). This sensor is used at startup to determine how much fuel to add or subtract. This is with the stock ECU, but I am sure MS has something similar for cold/hot starts.
Wiseco/Eagle, JWT S1 cams, BC valve springs, PT5857, ID1700 injectors, SR20DET ECU w/ Nismotronic, COP conversion with LS ignition coils, etc, etc...
--> YouTube channel --> my build thread
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Re: My '95 zenki build thread!

Post by TrackStarGT » Thu May 29, 2014 4:13 pm

Adamky, I think your right, I have been messing with the coolant based PW adder and it has helped. The car is running better and better the more I drive it. But there are a few kinks Id like to get worked out with the tuning. Such as: the clicking that Im getting with certain boost solenoid duty values, it makes a loud repetitive clicking/tapping noise. I would just like to get the table tuned right as well. Also, on deceleration from a rev, it drops below idle to about 400rpm then back up to idle around 1K. I would like it to not drop passed 1000 and feel more stable, still researching and trying to figure that out.
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sun Jun 08, 2014 7:50 pm

Got some more tuning done, the car is running great and pulling hard at about 10psi of boost. Im not going to run it higher than that until I throw bigger injectors at it. Even at 10-11psi I believe Im getting spark blow out at .032. I dont know if that is normal or not, but Im sure that problem will be solved with the COP upgrade that is in the very near future of the car. Also, at idle im getting a weird noise from the motor. it sounds metallic and sort of like a diesel but really soft not loud at all. Could it be valve lash? it aslo goes away when revved slightly, its only really at idle. Should I be worried? I broke the motor in with motomans method. So I hope that didnt have anything to do with it. Motor seems very solid and strong. Will probably take some video soon and post it..
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by shattabigz » Thu Jun 12, 2014 10:27 am

Nice build

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Re: My '95 zenki build thread!

Post by sdaigle240 » Thu Jun 12, 2014 5:53 pm

Good to see you up and running. I think your ok on that noise. Of course tough to say without hearing. I had/have a tick/clack at idle that also goes away with revs. When I brought it to the machine shop to have a listen (I assembled though) he toyed with it and said if it goes away with revs it's likely not valvetrain. That would change pitch. At least for me, it was just piston slap at idleish rpms. Turns out A lot of people have it, even on this forum, and it's not an issue really for anyone. My cause was 2 things. Arais pistons are known for it based on the type of material. And in my case I knew before we started thst my wall - piston clearances were a little over size due to three hones over the years and used pistons. Maybe it's just a lil ole slap? As for the gap my 14 would blow out .032 right around 10-12 as well. Think I ended on .028 when I was running 13.
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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat Jun 14, 2014 8:16 am

I humbly thank everyone who has commented and complimented my build. It really means a lot and helps when times get frustrating with the car.

The car is running awesome and putting a smile on my face everyday, I drive it to work everyday 25 miles one way. I couldn't be happier. There are a few little things here and there that need attention but over all it is a solid running machine.

I do however have a little electrical bug somewhere, sometimes my fans don't kick on which worries me. I hate intermittent electrical problems!!

Anyway, more to come soon, I decided NOT to go with the VAG coils, because there is a buffer circuit that is necessary to build and I just don't feel like messing with that. I can build it if someone were to give me a board layout, but I have done tons of research and can't find what I'm looking for and the guys over at msextra aren't getting me either so I'm going with Ls2 truck coils.
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Fri Jun 20, 2014 6:05 pm

heres how the 40 looks now.. sexy if I might say so myself!!Image

working on getting the ls2 truck coils mounted and implemented..ImageImage

bought a bank of coils that was still on the oem mounting bracket and harness connected, broke it down to the coils and striped harness to reconfigure wiring and rewrap.

as far as mounting which is always the stumper with this mod. I bent the tabs on these coil holding brackets so I can run a rod and spacers through it similar to aftermarket ls coil remote mounting kits.
Image

Image
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sat Jun 21, 2014 3:58 pm

got the mounting unit built, now working on mounting to engine...

ImageImageImageImage
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by shift_down » Sat Jun 21, 2014 4:51 pm

Oh nice fabrication. Good job on the coil mounting setup.
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Re: My '95 zenki build thread!

Post by TrackStarGT » Sun Jun 22, 2014 6:41 pm

Thanks shift! I cant wait to get these coils running, waiting on a harness conector!! Then its big injectors, flex fuel sensor, and e85, should be able to pull 400hp out of this turbo, muaahhhahhhaha :twisted:
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by S14wayz » Mon Jun 23, 2014 6:46 pm

looking great my man! Ehh careful with those spacers re-check the torque on em every once in awhile, I had a wheel come loose with my h&r spacers on my old s13 and the wheel literally came off when I was driving :/ 400hp sounds reasonable with the build!
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My S14 Build Thread
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Re: My '95 zenki build thread!

Post by thegreen240 » Sat Jun 28, 2014 5:21 am

This is the biggest inspiration i've had for boosting my KA. I couldn't decide between an SR or KA-t but now i've made up my mind. Thank you for being so thorough. I'll be boosting mine within the next couple months :mrgreen:

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Re: My '95 zenki build thread!

Post by TrackStarGT » Sun Jun 29, 2014 6:16 am

Wow!! thanks for those compliments! As far as the spacers yeah they freak me out that they are there. New wheels are on the to do list, and of course I will be buying some with the proper backspacing so no need for a dangerous failure point. However, that being said, The spacers are of high quality billet aluminum and have been torqued the **** out of.. Thanks for the heads up!
Daily Driver: 2010 Toyota Tundra CrewMax 5.7 TRD
Project and DD: 1995 Nissan 240sx Frankenstein

I live and breathe physics, mechanics, motorsports!!

My build thread viewtopic.php?f=40&t=60602

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Re: My '95 zenki build thread!

Post by thegreen240 » Sun Jun 29, 2014 7:23 pm

You should post some youtube videos of it running! I'd love to hear it.

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