Swedish KA-T *Now with new Bosch 2200cc EV14 injectors* :-D

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Niclas_AB
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Swedish KA-T *Now with new Bosch 2200cc EV14 injectors* :-D

Post by Niclas_AB » Wed May 16, 2007 9:08 am

Hello everyone!
At the moment i have a 1992 200sx with a ca18det. The last year iv'e been searching al over sweden for a ka24de to replace the ca18det.
They are very rare in sweden, think it's less than ten. But so a month ago i finaly found one that bought. So now it's finaly going to happend :D The plan is to make a fully built KA-T but it's going to take quite a while as I don't have the time or cash to do al at once.
What I know of, this is going to be sweden's first KA-T :D
Do you guys know of any KA-T's in Europe? :D
Last edited by Niclas_AB on Wed Apr 25, 2012 6:06 am, edited 6 times in total.

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Post by Niclas_AB » Tue May 29, 2007 3:58 am

Purchased and done so far:
*Ka24de :D
*Holset HX55 Turbo with billet compressorwheel (compressorwheel small dia 63mm and large dia 98mm)(Exaustirwheel 72mm). 19cm2
*1000cc injectors
They were to small so I'm about to replace them with 1600cc ones
*Custom made catchtank with Dual intank Walbro pumps and one walbro in the tank.

*Intercooler 24x12x4
*PRS 8 Standalone engine management
Now I'm running VEMS instead with a V3 harness

*CAD drawing of the turbo flange.
*Engine Gasket set
Blew the headgasket so I've replaced it with a 0.040 thick cometic MLS
Blew the headgasket again so I'm replacing it with a 0.060 thick cometic MLS
Currently Running a Felpro headgasket

*Make CAD drawings of the exhaust manifold flange
*Fabricate the items above
*New triggerwheel for the CAS(24+1)
*Exhaust manifold piping (20x90degrees bends and 7feet straight)
*HKS 50mm wastegate
Replaced with a HKS 60mm type 2 copy
*Forged rods (Eagle)
*Forged pistons (Wiseco)(9.1)
*ARP Head Bolts(10mm)
Drilled the block and head to accept 12mm bolts.
Had the whole rotating assamble balanced.
Decked and honed the block

*ACL Main bearings
*Clevite Rod bearings
*CAD Drawing of a wastegate flange
*Wastegate flange
*1 and 1/3 feet of fuel rail material
*Fuelrail fabricated
*Engine is assambled
*JGS customs RB20 Flywheel
*JWT clutchcover and disc(the disc was an exedy)
*Hose and fittings for the new fuelrail
*V-band flange to turbo
*Drill the oilpan
*Reroute the power steering lines to clear the exhoust manifold
*Honda CBR 600RR F4i coils
*4 inch airfilter
*Oil line in to turbo
*Oil line out of turbo
*New larger fuelfilter(Running a summit AN8 fuelfilter now)
*Make the exhaust
*Make the pipes to/from the intercooler
*New lower radiator hose
*MSD DIS 4+
Replaced with VW coils 115F
*Exhaust Wrapping
*Sparkplugs (Bosch of some kind)
Replaced with NGK BCR8ES
*Swoosch water and oiltemp meters
*VEMS LCD Display
*VEMS boost pressure controll valve
*VEMS Fuel pressure sensor
*VEMS EGT Sensor
* New 2,5bar boost gauge
* New aluminium radiator can
* 5-bolt conversion
* Dunlop 17-inch rims(8-front and 9-rear)
* Falken FK452 235/45 up front and 255/40 rear
* 300zx brakes al around
* Braided brake hoses al around
* 19-rows oilcooler
* Brian Crower 272 Cams
* Brian Crower Dual springs and titanium retainers
* Custom made Intake manifold by Me
* Q45 Throttlebody
* Ported and polished head by Mattias B
* New 50mm radiator, modified.
* 300zx gearbox
* 3.5l Custom made catchtank with dual intank walbros, fitted in the enginebay.
* Oil pressure gauge with custom adapter to make the sensor fit
* Custom made fuelfilter holder
* Power steering reservoir moved inbetween the watercooler and IC
* Braided AN8 feed line from the catchtank and braided AN6 return line
*3,5inch cold pipes
(Updated 2011-06-28)
Last edited by Niclas_AB on Mon Jun 27, 2011 10:44 pm, edited 27 times in total.

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Chozen
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Post by Chozen » Thu May 31, 2007 10:45 am

Welcome!

You are going to need more things. Get yourself a Z32 (91-96 twin turbo 300/FairladyZ)
mass air flow sensor. Look on ebay for that along with a downpipe and 3" catback.
You are also going to need some engine management. What is the highest octane fuel available in Sweden? You may have better options for engine management in Europe. There are a few ROM tuned ECU plug and play options here in the states. Then there is BikiROM from Australia, and a few other programmable ECUs. There is also always standalone, which I have a feeling would be easy to get ahold of in Europe, not sure of how easy it would be to get it tuned if you cant do it yourself though.

Most if not all of the things youre going to need are going to have to come from the USA. You can take your pick of forged pistons for the KA. I run Wiseco 9:1 pistons. There are a few brands and quite a few compression ratios to choose from. There are quite a few makers of forged rods also. All of which are in the USA. Look on Ebay for these things, or the shops that advertise here on this forum. AMS is a good place to get your entire rod/piston/bearing/headgasket package from. Find them here on the forum, and go see the website.

You can get most of the things you are thinking of fabricating on Ebay for a good price. A lot of knock offs of Japanese parts. I would suggest getting a good high quality cast iron log exhaust manifold from one of the shops that has a section here on the forum. Stay away from Ebay manifolds, most are known to crack. The bottom mount manifolds are good and cheap, with no problems that I have ever heard of. But with them you will be stuck with using a T25/T28 as that is what they are flanged for. Unless you want to use one and cut off the existing flange and weld on your own for the Holset you are going to use. Other things that dont need to matter as much like your turbo elbow, downpipe and catback exhaust you can save a lot of money buying on Ebay for cheap.
Last edited by Chozen on Thu May 31, 2007 10:58 am, edited 1 time in total.
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Post by JustS13R » Thu May 31, 2007 10:57 am

welcome to the forums and good luck on your build
JustS13R

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Post by Niclas_AB » Thu May 31, 2007 11:32 pm

Thanks :)
The Standalone management will come a little later on. Was then planning on using a MAP rather then a MAF, the Z32 Maf is getting quite expensive and aren't that easy to get hold of, here in sweden atleast.
Will be building my own exhaust manifold, there isn't any that i have found that utilizes the twin-entry design that this holset turbo has.
For exhaust I've made a 3" system for my ca18det that I will alter to fit the new engine/turbo.
The highest octane pumpgas available her in sweden is 99. But we use another measuring system than you, think there called RON and MON? So think it's about the same as you're highest octane. But Iv'e been running E85 for the past 2.5 years with nice result so was thinking of continuing with that.

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Post by BigLoukaT » Fri Jun 01, 2007 7:03 am

Just wanted to say -- good luck with the project, seems like a very cool and unique idea for where you live. I can't imagine having to import a ka to run a ka-t lol...I got my ka for free. :lol:

Good luck bro, keep us updated on the build.
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npx from 240sxforums wrote:i figure from my very limited knowledge about the 240 and under the hood about cars in general i would follow the sr20det trend.

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Post by Niclas_AB » Wed Jun 06, 2007 2:45 am

Got a sweet deal on a standalone management so I hade to buy it :D .
Don't know if anyone here uses it, it's a PRS 8 from perfect power. Theres like 3-4 cars with the ca18det that uses it here in sweden with nice results(400whp+) so it should hopefully work nice with the ka24de to.

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Post by SM240 » Wed Jun 06, 2007 6:21 am

nice,........ make sure and take pics man

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Post by Niclas_AB » Wed Jun 06, 2007 2:35 pm

So far I only have some crappy phone pics. But I'll try to get some nicer pictures later on. I'll be putting al my photos here:
http://200sx.kicks-ass.net/album/album. ... b&cat=6657
So far only a couple of pics of the engine and turbo.

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Post by turbonola » Wed Jun 06, 2007 8:27 pm

you should think about fabbin up an intake mani also since you can obviously fab things up yourself.
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Post by Turbo24sxt » Mon Jun 11, 2007 6:34 pm

E85 for the win .. and welcome to the forum .. my ka-t is also running on e85 and well it loves it thats all i can say ... good luck with everything and def keep us all informed ... i would love to see a 200sx (real one) with a ka ...

just like the guy on here doing the real silvia and 180sx with a ka-t :-D
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Post by 8-bit » Mon Jun 11, 2007 7:35 pm

very cool.. swedish KAT.. awesome.
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Post by Niclas_AB » Tue Jun 12, 2007 11:29 pm

Purchased an full engine gasket kit to now so I can begin to rip apart the engine for inspection. It's really very cheap to buy ka24de parts in the us. In sweden a full engine gasket kit is about 275$, and that's just oem parts.

Is there any visible difference between a 240sx, 200sx and 180sx? thought they only hade different engines?

A custom intake manifold will most likely be done to, as the injectors i have are topfeed and a different size so they won't fit. And then it's just as good to make a hole new intake rather than messing around with the old one. But I don't know how to weld aluminuim myself so i have to get some help with that.

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Post by Niclas_AB » Mon Jul 02, 2007 3:54 am

So, finally got something done this weekend. The gaskets has arrived so i ripped the engine apart and it looked almost new inside, no dirt or what so ever (will post some pics later on). The pistons was standard size so now i can order the rods and pistons. Also checked the flanges drawings I made and they seem to fit nice, so they will hopefully be made this week to.

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Post by Turbo24sxt » Tue Jul 03, 2007 11:58 pm

keep us updated for sure ... :D i want pics of the car this almighty KA is going into!
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Post by Niclas_AB » Wed Jul 04, 2007 12:04 pm

Well, som new pictures then:

The head and turbo flange: http://200sx.kicks-ass.net/niclas_ab/im ... 64e5c5.jpg
Cam cover off : http://200sx.kicks-ass.net/niclas_ab/im ... 7b6634.jpg
Hey almost new :lol:
New seats: http://200sx.kicks-ass.net/niclas_ab/im ... f512ee.jpg
The intercooler: http://200sx.kicks-ass.net/niclas_ab/im ... 9d08a7.jpg
PRS8 Unit: http://200sx.kicks-ass.net/niclas_ab/im ... 7a3580.jpg
A total of 42 wires to connect :shock:
Bet it will take a while to figure out....
The car chassi ain't that much to se, red, 17" wheel, removed rear wing, tinted windows, othewise nothing special that you notice. But I'll try to find some pics.

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Post by Niclas_AB » Thu Jul 05, 2007 1:02 pm

Well, here's a pic of the car then, it's not looking exactly like that anymore.

Image
It's a bit lower since I put on coilovers.

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Post by Niclas_AB » Sat Jul 14, 2007 3:44 pm

Here's a pic of the new vs the old triggerdisc
Image

It's was made for a sr20det so the inner hole is about 80degrees off.
I hope to be able to correct that by mounting the CAS 3 koggs "wrong". Obviusly won't work with distributor but if i go with coil on plug I can't think of any reason why it wouldn't work.

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Post by Niclas_AB » Thu Jul 19, 2007 3:06 pm

A little update again, finally began my vacation so now the old ca18det is out of the car and the ka24de is in for a testmount to see how much room there is for the exhaustmanifold and turbo.
Will post pictures tomorrow.

And here is some pics then:

Work in progress
Image

Old CA18det going out:
Image

Ka24de in the engine bay and testing where the turbo could fit.

Image

It ain't goning to be much room left but i think it could work.
Image

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Post by Niclas_AB » Mon Aug 06, 2007 3:11 pm

Here's a pic of the axhaust manifold as far as it's finnished, not quite sure where to put the wastegate tho... Any suggestion's?
Image

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Post by el tigre » Sat Sep 08, 2007 8:33 am

Dang! That looks pretty sweet! I would say, if you can deal with an open dump tube, run it off of the front of the manifold, closest to the front of the car, and shoot it strait down. Looks really good though man. You need to move this to the Pictures area in the forum, you will get a ton more complements, etc. :lol:
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Post by PSi » Sat Sep 08, 2007 5:50 pm

Ok im in love with the idea more than the swap... Kinda reverse JDM'age......

:lol:

I love it all your progress looks great too, keep up the great work...

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Post by Niclas_AB » Mon Sep 10, 2007 12:09 am

Thank you guys :D
I agree with that this thread would be better in the picture section. So if an moderator ses this, would you be so kind and move it :)

el tigre: The problem is that it's a twin scroll(think that's called in english ) so I have to run a pipe from each chamber to the wastegate, but i've found a way that hopefully will work.

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Post by el tigre » Mon Sep 10, 2007 9:41 am

Ahh yes. Good point about the twin scroll.

That turbo is huge. I am looking for an HX40 for my car at this point.
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Post by Niclas_AB » Tue Dec 25, 2007 9:01 am

So time for a little update, have had the engine in and out of the car a couple of times. Welded the exhaust manifold and fabricated the fuelrail. Bought a new fuelfilter(I think it's to a volvo) that are like alot bigger than the nissan filter, and it has M14 and M16 screw in connections so i made some connection pieces so I can run 10mm id hose everywhere. And I can also change the hose adapters and move up to 12mm if neceserry :lol: .
just a couple of pics than:

Image
Image

Hopefully it will happen quite some more the first days of next year as I have some days of from work

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Post by BigLoukaT » Tue Dec 25, 2007 7:17 pm

Still looking good Niclas! I havent forgotten about your 460cc injector swap offer, don't worry! Thanks again for the info on the injectors, and the offer, I'll let you know asap.
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npx from 240sxforums wrote:i figure from my very limited knowledge about the 240 and under the hood about cars in general i would follow the sr20det trend.

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Post by slos14 » Tue Dec 25, 2007 10:41 pm

wow man thats one clean car. :shock:
ka-t on the way
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Post by hcwt » Wed Dec 26, 2007 9:50 am

wow and to think i picked a ka up for 200 bucks and barely had to look around
they are just scorned here in the states i guess
"hey you got a ka you should get a Sr swap"
thats all i ever hear
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Post by jpadilla12 » Wed Dec 26, 2007 2:00 pm

The car is coming along very well. Are you running a 44mm Tial wastegate?

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Post by Niclas_AB » Sat Dec 29, 2007 5:26 am

jpadilla12: No, I'm going to be running a 50mm hks copy wastegate. I hear they will work fine if you take them apart and remove metal bits and such as is left from manufacturing.

New pic:
Image

and
Image

The turbo got a bit much angle uppwards and in against the engine, but it's not so much it's gonna cuase any trubble.
Unfortunally my welding wasn't god enaugh in the collector so I had some leakege there when I pressurized the manifold, so I still have some TIG welding to do :?

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