My 6L Manual WH2 Statesman

[SirNemesis]

I got it from eBay :)

http://www.ebay.com.au/itm/Vacuum-Manifold-350Z-WRX-EVO-VIII-SR20DET-Turbo-SILVER-/190543428368?pt=Race_Car_Parts&hash=item2c5d45fb10

[EV1LR8]

it looks like a good bit of kit, i was having boost problems cause there were to many boost reference line coming off the one Vacum

not sure if this will be a problem with urs just something to think about

[SirNemesis]

I don't think that will be an issue, I will be using the brake booster line as the feed.

[STATIE]

SirNemises - for someone that from what I can gather is not "in the trade" to do what you have done here by yourself is unreal.
Everything from bolting your own motor together, turbos, conversions & tuning etc :bow::goodjob:

[SirNemesis]

SirNemises - for someone that from what I can gather is not "in the trade" to do what you have done here by yourself is unreal.
Everything from bolting your own motor together, turbos, conversions & tuning etc :bow::goodjob:

Thanks mate, means alot. :) Certainly not in the trade, I sit in an office all day and don't even like getting my hands dirty.

[STATIE]

I sit in an office all day and don't even like getting my hands dirty.

Don't worry - I'm hearing ya.

[SirNemesis]

Dropped all the pipework off at Jet-Hot this morning, can't wait to get it back.

Did a test fit of my new strut brace. Looks good, still need to get some bolts and drill some holes.

http://www.zollenkopf.com.au/images/Statesman/Suspension/strutbrace1.JPG

Also started my Comp Cams rocker trunion upgrade.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg1.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg2.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg3.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg4.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg5.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg6.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg7.JPG

[chunkyvy]

Looking good mate !!! What are you using to trigger the water/meth injection. And at what boost level ? cheers

[SirNemesis]

The water/meth kit is self contained and will be triggered by boost. Will be starting to spray at 7psi and full by 15psi. Progressive system.

[SirNemesis]

Job done.

For anyone interested, I don't recommend this upgrade. I thought it was going to be a good idea but my impression has been changed. I wouldn't recommend doing this again.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg8.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg9.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg10.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg11.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg12.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg13.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/trunionupg14.JPG

[EV1LR8]

Hay mate, what kind of power u chasing ??

and what times ??

[SirNemesis]

Power, don't really know. I'd like to see a nice round 500rwkw but it doesn't mean much.

With times, again I don't expect much. I don't plan to compromise the 'package' so it will be faster down the 1/4 mile, so I will always be racing on 18" or larger wheels and won't be changing my brakes, etc. I'd like to see 135-138mph, and maybe a low 11 second pass.

[fishla]

I think the larger wheels will help you, as i've seen this thing struggle to get traction!! :burnout:

Pics of the pipes when they return ;)

[SirNemesis]

Just got the pipes back from Jet-Hot Coatings in Castlemaine. Bloody exceptional job I must say!

http://www.zollenkopf.com.au/images/Statesman/Turbo/jethot1.JPG

http://www.zollenkopf.com.au/images/Statesman/Turbo/jethot2.JPG

[hotbox]

very nice :goodjob:

[Millsy]

Farkin' awesome!!!

:goodjob:

Can't wait to see this thing back on the road

Cheers,

Millsy

[SirNemesis]

Won't be too long now Millsy :)

Couple of pictures from todays progress and a few more items crossed off the list.

http://www.zollenkopf.com.au/images/Statesman/Turbo/turbo20.JPG

http://www.zollenkopf.com.au/images/Statesman/Turbo/airfilter2.JPG

http://www.zollenkopf.com.au/images/Statesman/Turbo/airfilter1.JPG

http://www.zollenkopf.com.au/images/Statesman/Engine/engine20.JPG

I'm not 100% satisfied with the air filter bend/angle yet.

[JezzaB]

Still going to run the turbo beanie? Looks good mate

[SirNemesis]

Undecided if it will be required or not. It'll probably scratch off the coating if I try and use it so I really don't know if I should.

[JezzaB]

Undecided if it will be required or not. It'll probably scratch off the coating if I try and use it so I really don't know if I should.

Run the beanie mate.

Ive got full HPC on my VE on rear housing, dump, manifolds etc and it is still warm in there. Not enough to cook anything or be a concern but I wouldnt run it without a beanie. Plus keeping the heat in as much as possible makes the gas move faster.

[Dieselman]

Intake looks better now mate. It will be getting a bit more cold air now than it was getting from behind the headlight :goodjob::goodjob:


I will have to come for a fang in the big beast at our next meeting :):)


Ben

[SirNemesis]

Run the beanie mate.

Ive got full HPC on my VE on rear housing, dump, manifolds etc and it is still warm in there. Not enough to cook anything or be a concern but I wouldnt run it without a beanie. Plus keeping the heat in as much as possible makes the gas move faster.

Alright, will run the beanie. Cheers mate. :)


Intake looks better now mate. It will be getting a bit more cold air now than it was getting from behind the headlight :goodjob::goodjob:


I will have to come for a fang in the big beast at our next meeting :):)


Ben

Yep, hopefully a bit cooler and a bit more capacity. I don't know how much damage sucking warm air will be when the turbo is just going to heat it up anyway, but the ability to run an air filter about double the size has to be a win in itself.

Happy to take you for a drive next time :) :driving:

[WPN-383]

awesome build mate just read from start to finish, very well thought out modifications keep up the good work and cant wait to see this thing cruising around geelong... cruising in summer for sure

[Rub]

is this thing still not finished? :stick:

[SirNemesis]

is this thing still not finished? :stick:

Quiet you :jester:

Car is back on the road. Currently running on the 5psi wastegate spring only, but it still blows the tyres in 1st and 2nd. Had a little issue with the fuel quick-connects on the factory fuel lines (haven't changed the hardline yet). It blew off while I was cruising on the highway and drained my tank. Managed to clip it back on and limp to the servo. **** I hate quick-connects...

Fueling is way wrong with the regulator mounted up front. Rich everywhere, but consistant so at least I'm on the right track!

[SirNemesis]

Alrighty, update time. It's been awhile...

After changing the last lot of changes my car decided it didn't want to run very well. The changes involved Jet-Hot coating the pipes, installing the rocker trunions and changing the fuel system around. Naturally I suspected fuel system changes were the culprit, but after checking that several times I discovered that the problem was actually lifter preload.

Apparently, the slack in the factory rocker bearings was enough to change my preload. When decent bearings were installed I lost my preload and the valves were being ever so slightly held open when the engine was cold. Swapped over to 7.350" pushrods and we're good as gold again!

This wouldn't have been an issue with factory lifters, but as the Morel/PBM lifters have such a small preload window it caused me issues.

Been driving it around for a little while on 5psi and it is bloody powerful, but a few rattles and bangs from the back end have motivated me to pull it apart.

Car is currently on the hoist with the rear end ripped out. All rear end bushes are being replaced, new camber kit, new tailshaft doughnut too (again!).

Also taken this opportunity to run the 1/2" fuel hardline down the chassis. Job done, just need to fit it all up now. Pictures on the weekend hopefully.

[HEKYEH]

Should be good.....ONCE you finish it! :toetap:

[tmob]

I am looking forward to seeing this thing on the road.... maybe at the next cruise?

or the one after that...



...or even the one after the one after the next one..



eh.. stuff it.... Pics will do... will sit tight for tomorrow..
:yup: :p

[SirNemesis]

Little teaser video on 5psi.

0bdrZLlL_R0

[v8dude78]

That sounds insane :bow:

[NASTY_LS1]

Looks unreal man, I'll definitely try and keep up with this thread

[maka5]

hahahahha love the laugh at the end... cnt wait to see this thing when its 100%

[paok_18]

that sounds insane buddy! :goodjob:

[SirNemesis]

It's been awhile since I've updated this. I haven't really changed anything...

The car has been working really well and I'm enjoying it! I made a little change on the weekend just cleaning up the fuel line routing in the engine bay. Loom will be next...

http://www.zollenkopf.com.au/images/Statesman/Fuel/fuelsyseng1.JPG

[SirNemesis]

Successful day at C&A Auto Fashion on Saturday. Managed to get 442.4rwkw on 11.5PSI, on a stinking hot day. Still plenty more in the tune, and I'll be putting more boost into it than that.

http://www.zollenkopf.com.au/images/Statesman/tropheys1.jpg

[SS317]

Nice work mate :goodjob:

[macca33]

Congrats mate, it is a stellar effort for a home mechanic / tuner job. :bow:

[Tryhard]

Well done indeed,congratulations mate.

[solid]

Good work there mate considering the heat. Have you got a copy of the dyno sheet?

[ittwgn]

nice work push that boost up to 16+ and 500 rwkw should be there !!!!!!although i,m guessin with the m6 the power already would be nuts!!!!

[Dieselman]

Great result mate :dance::dance:

[Wonky]

Very short clip of this beast spooling up and coming alongside me on a cruise we were on on Thursday. Going through the tunnel(s) lots of cars were revving but to me the sweetest sound was this bit! :yup:

http://youtu.be/y6zEcjA-SI0 (apologies for the music that was playing :doh:)

[Wonky]

James (paok_18) - hope you only disliked the previous post due to my music and not because as a Statesman owner you don't like M6 turbo Statesmans? :confused:

[VY-SV8]

only 4secs?? thats only just startin to spool.... i wanna hear that beast snarl!

as a side note i am strongly considering bolting a big ass hairdryer to the side of mine, however i really wanna keep the turbo spooling sound to a minimum and keep the V8 bark... is this even an option by keeping the boost low and some clever piping or am i just gonna have to live with it?

[Wonky]

only 4secs?? thats only just startin to spool.... i wanna hear that beast snarl!

I have a "black box" video cam which runs permanently with ignition on (inc. GPS and Google maps) but unfortunately Adam stopped at that point just as he appeared in frame, so that's all I got. I would have loved him to keep on going too!!

[VY-SV8]

holy shit man, i just had to look out of my balcony to make sure you weren't stalking me bro. Then i read your post another few times before realising you were talking about nemesis. hahaha. Guess adam isn't exactly an uncommon name.

any ideas on the second part of my post? you seem to have been around his car a bit.

[Wonky]

No unfortunately - not had much to do with turbos and only met Adam a few times on cruises etc. as he lives waaaaaay the other side of Melbourne well over 100kms from me. He or Jezza@HDTCQ amongst others should be able to answer your questions.

[SirNemesis]

only 4secs?? thats only just startin to spool.... i wanna hear that beast snarl!

as a side note i am strongly considering bolting a big ass hairdryer to the side of mine, however i really wanna keep the turbo spooling sound to a minimum and keep the V8 bark... is this even an option by keeping the boost low and some clever piping or am i just gonna have to live with it?

It all depends on how you drive I feel. One of my intentions with buying the larger turbo originally was so I could drive it all day every day without even hitting boost if I wanted to, which I can still do. A turbo car will never have that same V8 note, but it can still sound pretty good. The way I have my car is I have plenty of compression and cubes, so theres plenty of power without hitting boost. Boost is just the icing on the cake.

[***VX*R8***]

That sounds awesome spooling up. Definitely a sleeper and very unique (IMO).
Would love to see some more vids...

[hotbox]

Successful day at C&A Auto Fashion on Saturday. Managed to get 442.4rwkw on 11.5PSI, on a stinking hot day. Still plenty more in the tune, and I'll be putting more boost into it than that.

http://www.zollenkopf.com.au/images/Statesman/tropheys1.jpg

Nice work lad

[SirNemesis]

vnETbLPb3Bo

[dazzrael]

faaaarrck yeah! now that is a sound! been watching this thread for a while, well done adam (i know you from another forum....)

[SirNemesis]

So, I bought some stuff. I do enjoy starting new projects before finishing the ones I've already started...

http://www.zollenkopf.com.au/images/Statesman/coilcoverscambags1.JPG

[Millsy]

I'll send you pics for the drag bag install ;)


Cheers,


Millsy



LS9 cam?!? :D

[SirNemesis]

I'll send you pics for the drag bag install ;)


Cheers,


Millsy



LS9 cam?!? :D

Thanks Millsy :)

Yep, LS9 cam, still haven't decided if I'm going to use it.

[SirNemesis]

So, I spent some more money and bought some toys from Revshift.

I bought a pair of their aftermarket tailshaft donuts, and a poly transmission mount insert.

The tailshaft donuts appear to be very well made, the poly transmission mount insert is very poorly made but will still do what it is supposed to do.

First thing I did after pulling the tailshaft out is weigh the old and new donuts. Interestingly, the stock rubber ones are about 70g heavier than the alloy Revshift ones.

http://www.zollenkopf.com.au/images/Statesman/Driveline/donutoldweight1.JPG

http://www.zollenkopf.com.au/images/Statesman/Driveline/donutnewweight1.JPG

The rear stock donut wasn't too badly damaged as can be seen in the pictures above, but the front one (below) isn't so healthy.

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut1.JPG

While fitting the new donuts to the tailshaft I noticed that the inner sleeves stick out a bit on each side (3 each, offset). I cannot see any reason why this would be required, and it doesn't appear this way on the instructions. I did notice that the 2005-2006 images on the Revshift website show these inner sleeves sticking out like this, but the 2004 model flush with the bush.

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut2.JPG

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut3.JPG

I made the assumption that they've sent me the wrong items and cut the sleeves down to suit. This might have been the wrong thing to do, I'm still not sure...

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut5.JPG

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut4.JPG

I've reinstalled the tailshaft to the same position it was in originally (I marked it prior to removal) and also installed the transmission mount insert. Initial drive was interesting. There is noticably less vibration at low speed and with more throttle, which is exactly what I wanted. Gear changes are also much nicer, no lash, much firmer and a noticable thump if not so careful on the clutch. I didn't get a chance to really give it some throttle as its raining today, but I think it will work quite well.

What I did notice though is I have a bit of vibration over 120km/h. I didn't push it faster than this, but it will be something I need to look into before I take it to the drags next.

[255-LS1]

nice couplings! are they the same part front and rear?

any reason you selected the 05-06 part over the 04?

[SirNemesis]

nice couplings! are they the same part front and rear?

any reason you selected the 05-06 part over the 04?

Same front and rear. I didn't select the 05-06, I ordered the 04, and received the 05-06. I'm assuming the only difference is the sleeve length instead of actually being thinner in the bush.

[255-LS1]

cheers. might have to look into these. was going purchase some hardy spicer ones for mine, but for the price think these are a winner. also no more slop slop

[SirNemesis]

Update!

http://www.zollenkopf.com.au/images/Statesman/Interior/transmission0.jpg

[zorro]

Interesting Adam very interesting.....


GM: Has millions of dollars and highly trained engineers.

Some guy in his backyard: Has a hole saw.

[ittwgn]

update ?? hole in floor!!!! nice pics in street comms!!!! qoute- not bad for an unassuming wh stato!!!! cheers

[SirNemesis]

update ?? hole in floor!!!! nice pics in street comms!!!! qoute- not bad for an unassuming wh stato!!!! cheers

Yep, special hole-in-floor update ;)

I have a pic in Street Commodores? Tell me more...

[zorro]

I'll assume you a gay if you put an auto in it :lol:


GM: Has millions of dollars and highly trained engineers.

Some guy in his backyard: Has a hole saw.

[ittwgn]

Yep, special hole-in-floor update ;)

I have a pic in Street Commodores? Tell me more...

joining me with full manual t400 conversion???? yeh mate there,s a write up about the c&A dyno day that you won of course !!! few pics one on the rollers and an engine bay pic and the unassuming wh stato qoute!!!cheers

[SirNemesis]

I'll assume you a gay if you put an auto in it :lol:

Awww :(




joining me with full manual t400 conversion???? yeh mate there,s a write up about the c&A dyno day that you won of course !!! few pics one on the rollers and an engine bay pic and the unassuming wh stato qoute!!!cheers

Sweet, what issue #?

I'm thinking 4L80e as I want to keep overdrive and electronic control, but I'm putting a stock 4L60e at the moment (yes, I know it wont last long) as that's all I can afford at the moment.

[ittwgn]

4l80e is not cheap but great from all my research!!!! would imagine make the car so much easier to drive!!mine i think would be crazy with an m6!!! your in the latest issue no 198 that i got in the mail midweek!!! i will have my turbo and cold side setup for sale soon if you want to step up to t6 1.32a/r !!! need t6 hot side tho!!! anyway cheers

[EV1LR8]

NO not another manual Turboed LS converting to auto :(

[dogsballs]

au revoir manuale!

[EV1LR8]

still havnt put the 88m on yet mate ? whats the turbo your running now ?

[zorro]

Sweet, what issue #?

I'm thinking 4L80e as I want to keep overdrive and electronic control, but I'm putting a stock 4L60e at the moment (yes, I know it wont last long) as that's all I can afford at the moment.

All good mate, if you aren't doing mountain runs or track days an auto will suit it a lot better. will be interesting in a straight line, if you can keep it straight :lol:

Let us know if you need a hand wouldn't mind a run out to Geelong


GM: Has millions of dollars and highly trained engineers.

Some guy in his backyard: Has a hole saw.

[SirNemesis]

Heh yep, was time for a change.

Zorro, an extra set of hands is always appricated. I'll be working on it in a few weeks, will let you know.

[SirNemesis]

Auto cooler has arrived. Should do the job :D

http://www.zollenkopf.com.au/images/Statesman/Driveline/autocooler1.jpg

[GR346]

Had a couple of pages to catch up on but damn she is looking nice.
Great work mate, loving the car and that sounds :)

Looking forward to the next update

[itsme4g63]

very noice saloon!

[SirNemesis]

More stuff!

http://www.zollenkopf.com.au/images/Statesman/Driveline/autobits1.jpg

[dazzrael]

what size converter are you going adam.....? is that 4l60 still in one piece!?

[SirNemesis]

The converter is 3000rpm, but might actually stall a bit higher as it depends on torque. At the moment the 4L60e is in one peice, but I haven't put it in my car yet ;)

[SirNemesis]

Progress...

http://www.zollenkopf.com.au/images/Statesman/Driveline/converter1.jpg

http://www.zollenkopf.com.au/images/Statesman/Driveline/converter2.jpg

[GR346]

Looking good mate, keep the pics coming :)

[SirNemesis]

Added some black fuel rails and AN-8 nylon braided line. Also got rid of the nasty quick-connect fittings on the hardline and used some compression fittings instead.

http://www.zollenkopf.com.au/images/Statesman/Fuel/blackfuel1.JPG

http://www.zollenkopf.com.au/images/Statesman/Fuel/blackfuel2.JPG

http://www.zollenkopf.com.au/images/Statesman/Fuel/blackfuel3.JPG

and, the transmission cooler fits!

http://www.zollenkopf.com.au/images/Statesman/Driveline/autocooler2.JPG

[SirNemesis]

So, I've been doing some playing with the water/vapour ports in the head. Engines VX+ had these rear ports blocked off, which for NA engines isn't a problem, but apparently can cause a lot of excessive heat on the rear of the heads when playing with boost. This is something that I want to avoid, and I've heard of a lot of people who play with boost opening them up and venting them to the radiator (like on VT LS1 engines). The problem is, the VT LS1 has a different manifold with clearance underneath to run the lines. I don't have this clearance, so I needed to get a bit creative.

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour10.jpg

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour11.jpg

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour12.jpg

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour13.jpg

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour14.jpg

I would love to hear some opinions from anyone who has researched this before, or feels that my idea will or won't work. Don't be scared, I can handle a bit of criticism.

[SirNemesis]

And the finished product. I'm pretty pleased with it, just need to wait for the last t-peice to arrive for the front.

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour16.jpg

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour15.jpg

[Evman]

That looks brilliant. It'd be difficult to compare results but the idea is solid. Any idea why they're blocked off in the first place?

[SirNemesis]

I imagine GM determined it wasn't essential for a standard engine, so took the cheaper option.

[duke5700]

Looks good and even the bends are semi neat :p.

I can't see why it would hurt in anyway, not having hot pockets in the heads is always a good thing I would think.

[SirNemesis]

I did some more work on the car today. Not much, but a bit.

New timing cover with seal installed.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/timingcover1.jpg

Took the old timing cover off, still nice and clean in there.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/timingcover2.jpg

Nice new timing cover installed.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/timingcover3.jpg

Then I decided to cook up some tasty balancer for lunch...

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/balancer10.jpg

Shame it turned out to be the wrong balancer (VE/Corvette shallow style), and I didn't notice until AFTER it was installed....

[BTS666.0]

So, I spent some more money and bought some toys from Revshift.

I bought a pair of their aftermarket tailshaft donuts, and a poly transmission mount insert.

The tailshaft donuts appear to be very well made, the poly transmission mount insert is very poorly made but will still do what it is supposed to do.

First thing I did after pulling the tailshaft out is weigh the old and new donuts. Interestingly, the stock rubber ones are about 70g heavier than the alloy Revshift ones.

http://www.zollenkopf.com.au/images/Statesman/Driveline/donutoldweight1.JPG

http://www.zollenkopf.com.au/images/Statesman/Driveline/donutnewweight1.JPG

The rear stock donut wasn't too badly damaged as can be seen in the pictures above, but the front one (below) isn't so healthy.

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut1.JPG

While fitting the new donuts to the tailshaft I noticed that the inner sleeves stick out a bit on each side (3 each, offset). I cannot see any reason why this would be required, and it doesn't appear this way on the instructions. I did notice that the 2005-2006 images on the Revshift website show these inner sleeves sticking out like this, but the 2004 model flush with the bush.

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut2.JPG

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut3.JPG

I made the assumption that they've sent me the wrong items and cut the sleeves down to suit. This might have been the wrong thing to do, I'm still not sure...

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut5.JPG

http://www.zollenkopf.com.au/images/Statesman/Driveline/donut4.JPG

I've reinstalled the tailshaft to the same position it was in originally (I marked it prior to removal) and also installed the transmission mount insert. Initial drive was interesting. There is noticably less vibration at low speed and with more throttle, which is exactly what I wanted. Gear changes are also much nicer, no lash, much firmer and a noticable thump if not so careful on the clutch. I didn't get a chance to really give it some throttle as its raining today, but I think it will work quite well.

What I did notice though is I have a bit of vibration over 120km/h. I didn't push it faster than this, but it will be something I need to look into before I take it to the drags next.


hey mate, awesome build. i am waiting to hear back from rev shift guys so i can order one.

[SirNemesis]

I'd recommend against it. They aren't a perfect fit, I'm not happy with the vibrations mine causes, and I know another guy who isn't happy with them either. I can see me changing back to either standard or a VT-style tailshaft soon enough.

[BTS666.0]

bummer. did you try the instructions on adjusting the tranny to get rid of vibrations? they are on the website. is there any other product like this?

[SirNemesis]

You know, I didn't see these recommendations for shimming the mount previously, but I did read this document. Perhaps I'm blind, or perhaps they are new. I'll give it a try once I get the car back on the road and report back.

As far as alternative products, I don't know of any. I know that BMW flex discs will also fit, and I know that the E92 BMW M3 (and probably others) has a factory flex disc which is much like the Revshift item. Cast alloy body, rubber inserts. Might be a better option, depending on price...

[hotbox]

do the steam bleeds still return to the top of the radiator?

[SirNemesis]

Yep, returns to the radiator from here.

http://www.zollenkopf.com.au/images/Statesman/Cooling/vapour11.jpg

:)

[SirNemesis]

Not much to update at the moment, slow progress.

My oil pressure adapter arrived.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/oilpres1.jpg

Also toying with the VZ radiator setup again. New radiator and shroud, VZ V6 (I think) fans. The wiring is different, might be able to make it work though.

http://www.zollenkopf.com.au/images/Statesman/Cooling/vzradiator1.jpg

http://www.zollenkopf.com.au/images/Statesman/Cooling/vzradiator2.jpg

[RRR888]

SirNemesis I have just flicked through your thread for about the 1000th time - love your work mate, your DIY attitude is awesome.

[SirNemesis]

Thanks mate :)

[SirNemesis]

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/engine30.jpg

Nearly done...

[dazzrael]

how long you reckon that stock 4l60e will last.....?

[SirNemesis]

Hopefully it'll survive until C4C on Sunday. After that, who knows...

[solid]

There will be no gear shifting excuses when you race now... Are you going to have a quarter pass with the stock trans? I would and see how it goes

[SirNemesis]

I just fired it up and went for a drive around the block. Something is very wrong with the box already...

[solid]

Ooh dear.... Pop another stock on in there and go for another lap

[BTS666.0]

hey mate, how did you go with the revshift donuts?

[hotbox]

steam bleeds look tidy lad top work

[SirNemesis]

Well, its official. The auto is ****ed, didn't even make it to the end of the street. O'well.

[SirNemesis]

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/failed10.jpg

[RARASV8]

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/failed10.jpg

not good!

Garry

[jca]

what was the give away was it pushing water or misfire or both?

[SirNemesis]

what was the give away was it pushing water or misfire or both?

Bit of occasional white spoke while idling at the lights, and low compression on #5 when tested.

Didn't push or use any water.

[jca]

Time for cast block

[SirNemesis]

Time for cast block

It was a cast block ;) Cast aluminium...

Time for a cast iron block, yes.

[SSWAGZ]

Love the car mate. How many Kim's did you get out of the motor before that happened?

Just a shame I couldn't see any of the pics till page 16 :(

[SirNemesis]

Love the car mate. How many Kim's did you get out of the motor before that happened?

Just a shame I couldn't see any of the pics till page 16 :(

Web host is currently offline, it should be back tomorrow. I do have all of the pictures hosted elsewhere as well but I can't update the links on this forum. I got about 25,000k's out of the engine since the rebuild.

[SSWAGZ]

Will be checking back to see the rest of the pics for sure :)

The internals still useable in a new block?

[SirNemesis]

Should be but won't know for sure until I've stripped the block. I imagine it will be fine though.

[SSWAGZ]

You seem to have caught it before it got terminal. So hopefully for your sake you did catch it before anything other then the block got damaged.

[solid]

Ooh dear my son. What on earth have you been doing to that poor thing for that to happen...

[SirNemesis]

Ooh dear my son. What on earth have you been doing to that poor thing for that to happen...

Rubbish turbo kit, what can I say... :P

[SirNemesis]

http://www.zollenkopf.com.au/images/Statesman/Engine/enginebay30.jpg

Progress...

[SirNemesis]

It begins...

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/block100.jpg

[RARASV8]

what size will this be Adam?

Garry

[SirNemesis]

Still going to use the same 390ci rotating assembly, unless I find some damage to it when I pull it down. If the pistons are damaged, I might go 427ci.

[SirNemesis]

Not bad progress for the day...

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/engineblock100.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/storage1.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/storage2.jpg

Rather unhappy looking main bearing. I thought I put in alot of effort to ensuring the block was clean, but apparently I didn't!

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/bearing101.jpg

[VendeTTR]

Keep at it mate, will be killer once done.

LS coffee table?

[SirNemesis]

Coffee table is the plan :)

[VendeTTR]

Ohh yes, i already have an LS1 table :) post up that when your done too

[blackvussii]

Hey mate, great build and well done doing it all yourself. Any damage to the rotating assembly? With the new bearings will you have to resize anything? I'm slowly getting parts together for a budget build using second hand internals... Would be keen to know what sort of tolerances and ring gaps you are aiming for when you put the short block together...

[SirNemesis]

Hey mate, great build and well done doing it all yourself. Any damage to the rotating assembly? With the new bearings will you have to resize anything? I'm slowly getting parts together for a budget build using second hand internals... Would be keen to know what sort of tolerances and ring gaps you are aiming for when you put the short block together...

Thanks :)

I don't think I'll need to use different size bearings, but I won't know until I get the crank and block back. I'm thinking I wont as the crank is only getting a polish. I'll post up the tolerances and gaps up as I do it.

All going well I should finally get the block back from the machine shop tomorrow. They are just waiting on cam bearings at the moment.

I picked up some seals from Spencer Race Engines today and glued them into the rear block cover and the cam retaining plate. The LSX block is a little different than typical LS engines with these seals. The LSX has o-ring grooves, where the other blocks use bonded seal plates. This makes the LSX a bit dicky, but I got them glued in nicely.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxplates1s.jpg

My new rings also arrived from Total Seal.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxrings1s.jpg

:)

[vxssblown]

Looking good cant wait to see this back together, it will be a beast.

Just curious how much lag is there with these single turbo kits ? when does boost come on?

Cheers

[SirNemesis]

Looking good cant wait to see this back together, it will be a beast.

Just curious how much lag is there with these single turbo kits ? when does boost come on?

Cheers

Thanks. Very little lag with this kit, full boost by 3000rpm. I've sold the kit to another forum member now though and will be doing something a little different this time around.

[SirNemesis]

Ok, now I have some progress to talk about :)

Got the block back from the machine shop, was a bit disappointed they hadn't touched the mains as I specified I wanted them line honed. The guy at the machine shop was confident that I wouldn't need to as they measured up good and suggested I do a pre-assembly and bring the block back if it isn't right. I'd need to bring the block back to do the deck as it also hasn't been cut yet. This is because I need to measure piston height before I know how much of the deck to cut back.

So, first things first I need to get the heavy bastard out of the crate and onto the engine stand. This little gizmo made the job easy.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxblockstand1s.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxblockstand2s.jpg

Done! Ready to put the crank in. Flipped the block and removed the factory main bolts and caps.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxblockmains1s.jpg

Mmmm dowels...

3 of 5 the caps had burs on them which would stop them seating correctly, all in the same position. A little work with the diamond file cleaned these up.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxblockmains2s.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxblockmains3s.jpg

Then I went over the surface area with some emery paper to remove any little specs of rust which had formed.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxblockmains4s.jpg

Mmmm billet...

Put the bearings in. Cleaned and rested the crank in dry and added some Plastiguage. Measured the clearances and found about 0.0008" for all. This is wayyy too tight, so will need to be machined out to achieve the desired 0.0025-0.0030" clearance I'd like.

Removed the Plastiguage, cleaned the bearings and added some assembly lube. Put the crank back and torqued down the caps to spec. When torqued, the clearance is too tight to allow the crank to turn by hand, which won't help me with the next stage. Loosened off all of the mains to just over finger tight, which allowed me to turn the crank.

Cleaned up a couple of pistons and installed. Measured the deck to piston clearance which appears to be about 0.0021-0.0022".

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/lsxdeck1s.jpg

Also went through and gapped all of the rings to suit. 0.0022" for the top ring, 0.0014" for the bottom ring, as per Total Seal recommendations.

Tomorrow I'm going to try getting the block back to the machine shop to do the rest of the job. Hopefully it wont take too long!

[SirNemesis]

Progress!

0.0025" clearance on the mains and rods. Block zero-decked, all looking sweet :)

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/crank101s.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/engine101s.jpg

[Evman]

Loving the progress mate

[hotbox]

looking good mate

[kosta2577]

like it mate asewome car

[SirNemesis]

Not much progress tonight. I installed the cam and the windage tray...

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/windage1s.jpg

But then I noticed a few holes in this block. I've never worked with a brand new block before, so no doubt this is normal and I just need to get the bits.

Q&A time...

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockplug1s.jpg

#1 What goes in here? Is this where the barbell restrictor goes? Does it just sit in there or do I need a cap to keep it in place? Can I reuse the one from my LS2 block? Are they the same? Should I buy a new one?

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockplug2s.jpg

#2 Does something go in this hole? This is on the rear of the block (upside down in the photo) and is threaded.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockplug3s.jpg

#3 What about this hole? This is at the rear of the block (upside down again). I assume something goes in here? What is it? Is it just a plug? Does anyone know the part number(s) for these bits?

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockplug4s.jpg

#4 What about this one? This is at the front of the block near the oil pump outlet (upside down block).

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockplug5s.jpg

#5 And these? These are on the rear on the block outside the rear plate. This are in the coolant galleries and there's 1 on each side of the rear of the block. The front appears to have them as well, but the front ones are already plugged?

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockplug6s.jpg

#6 What about the one on the right here? The left is the outlet of the oil pump, but I'm not sure what goes in the right hole (if anything). It kinda lines up with a flat part of the front cover, but I imagine something needs to be pressed in here first?

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockcamplate0s.jpg

#7 This hole in the cam retainer plate (upside down photo) isn't round like the others. I've done some googling and it appears to be normal, but it means the tapered bolt doesn't sit flush with the plate like the others do. Should I cut the taper deeper and make it round? Doesn't seem to cause any problems, but I don't really understand why its odd.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockcamplate1s.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockcamplate2s.jpg

The block didn't come with bolts for this plate so I'm using the one from my LS2/L76. The problem is the LS2/L76 only has 4 where the LSX has 6. I assume they are the right thing? If so, I'll buy some more tomorrow.

That's all I've got to show for now. Hopefully someone who's played with these blocks before can help with the questions :)

[duke5700]

I have a barbell if you need it, 2, Its M16 x 1.5 and goes into the rear oil gallery, I plumbed my accusump in there.... and I'm done.

[SirNemesis]

I have a barbell if you need it, 2, Its M16 x 1.5 and goes into the rear oil gallery, I plumbed my accusump in there.... and I'm done.

Thanks boss. Still stuck on the one at the back of the block. My LS2 block doesn't have a hole there and GM can't help me...

[SirNemesis]

Ok, progress for today...

I've ordered a barbell oil restrictor for the rear of the block and got some plugs coming which should suit the big holes on the rear of the block. I also managed to get 2 of 3 plugs from my old LS2 block, stripped the 3rd one attempting to remove it, so I'll order another one of those.

Picked up 6 new cam retaining bolts today from the bolt shop. GM wanted $9each for them which I couldn't justify. The off-market ones are allen head instead of torx, and about 2mm longer, but they don't bottom out in the block and torque up fine.

Got the timing chain on, the oil pump, pickup and sump.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blocktiming1s.jpg

Also put the lifters in, the head studs and put the head gaskets on. I still need to do some cleaning to the heads before I put them on so I'll do that tomorrow.

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockstud1s.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/blockgasket1s.jpg

Still stuck on the plug that goes on the rear of the block, behind the rear plate next to the cam. Its the same thread as the other ones on the block, but the head of the plug doesn't fit in the hole on the block, which stops the rear plate seating properly. Not sure what to do about that yet...

[blackvussii]

http://books.google.com.au/books?id=crikJiTbRAAC&pg=PA97&lpg=PA97&dq=lsx+block+plug&source=bl&ots=nqcFdxTsQE&sig=1qt7GqGXqsZ4P1vQ0KUHmgfaou0&hl=en&sa=X&ei=faeKUaQgh5WIB9TlgOAE&ved=0CDUQ6AEwATgK

hopefully this link works, mentions maching the plug down because its common for them to sit proud

[jca]

Hi from memory the last lsx I did come with a plug kit and all the bolts etc for the rear /cam plates did u get it from eagle ?

[SirNemesis]

http://books.google.com.au/books?id=crikJiTbRAAC&pg=PA97&lpg=PA97&dq=lsx+block+plug&source=bl&ots=nqcFdxTsQE&sig=1qt7GqGXqsZ4P1vQ0KUHmgfaou0&hl=en&sa=X&ei=faeKUaQgh5WIB9TlgOAE&ved=0CDUQ6AEwATgK

hopefully this link works, mentions maching the plug down because its common for them to sit proud

Thankyou! I've been researching like a madman and finding nothing. That's perfect :)

[SirNemesis]

Hi from memory the last lsx I did come with a plug kit and all the bolts etc for the rear /cam plates did u get it from eagle ?

I'm getting mixed reports on what they are supposed to come with. Some people say with all plugs, some say missing some plugs. It came from eagle originally, but it's been sitting in some guys lounge room for months in between, so it may have come with the plugs and gone missing at some point.

[feistl]

Thankyou! I've been researching like a madman and finding nothing. That's perfect :)

Hey mate,

If you need any more info from this book i can assist. I work in a Library and turns out we have that book on the shelf here (Literally about 50 meters away from where im sitting now :P). I'm gonna grab it for a read anyway...

Cheers

[SirNemesis]

Hey mate,

If you need any more info from this book i can assist. I work in a Library and turns out we have that book on the shelf here (Literally about 50 meters away from where im sitting now :P). I'm gonna grab it for a read anyway...

Cheers

Thanks mate. As it turns out... I already have a copy of this book too lol. I should probably read it...

[jca]

did u get the lifter trays/ bolts etc the last one i did had it all bagged up with the lifter trays/ bolts/ plugs/ dowls etc but the first one i did i brought new but s/h and reckon the fellow had throw most of the extras over his shoulder drop and see spencer i know for sure if there meant to come with them cos its a pain trying to buy parts for the lsx block my itself.

[SirNemesis]

did u get the lifter trays/ bolts etc the last one i did had it all bagged up with the lifter trays/ bolts/ plugs/ dowls etc but the first one i did i brought new but s/h and reckon the fellow had throw most of the extras over his shoulder drop and see spencer i know for sure if there meant to come with them cos its a pain trying to buy parts for the lsx block my itself.

Nar, didn't get the lifter trays or plugs, but that's OK I'm not using them anyway. I dropped into SRE yesterday but he's closed, moving to a new location. He's already helped me out once with the seals for the cam retainer and rear plate, good bloke. If I don't have any luck elsewhere I'll drop in and see him again.

[SirNemesis]

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/engcompl1s.jpg

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/engcompl2s.jpg

[blackvussii]

Nice, looks neat.

[LuisS]

Subscribed ;)

[Toddler78]

http://www.zollenkopf.com.au/images/Statesman/Engine/390ci/LSX/engcompl2s.jpg

Question: is there any reason youve run the braided line for the fuel rails from the rear to the front on the other side? Ive always just seen them connected on both fronts.

[zorro]

Fail for not putting this motor in the Lolvo

[SirNemesis]

Question: is there any reason youve run the braided line for the fuel rails from the rear to the front on the other side? Ive always just seen them connected on both fronts.

Yep, couple of reasons actually. It is a case of personal preference, but for me, running the crossover at the front made it too close to the bonnet for my liking, and also too close to the throttle cable. If it was an electronic throttle then it'd be OK, but I didn't like it.

I'm also running 1/2" hardline to the firewall just next to the booster. I couldn't get a nice hose shape between this hardline and the rail to compensate for engine twist under torque. I felt more confident running the line to the front of the rail so it wouldn't pull on the hardline or fittings. :)


Fail for not putting this motor in the Lolvo

Don't speak too soon... I will most likely put this in the Volvo eventually, but not until I've at least run a 10 with the Volvo and a stock engine...

[zorro]

Tough!!!!

10 chars

[Toddler78]

Yep, couple of reasons actually. It is a case of personal preference, but for me, running the crossover at the front made it too close to the bonnet for my liking, and also too close to the throttle cable. If it was an electronic throttle then it'd be OK, but I didn't like it.

I'm also running 1/2" hardline to the firewall just next to the booster. I couldn't get a nice hose shape between this hardline and the rail to compensate for engine twist under torque. I felt more confident running the line to the front of the rail so it wouldn't pull on the hardline


Don't speak too soon... I will most likely put this in the Volvo eventually, but not until I've at least run a 10 with the Volvo and a stock engine...


Cheers for explaining that :goodjob::cheers: