nathans VY Calais - 'Calais 2.0' - 6sp Manual, LS1 V8, Sunroof, Blue Leather

[nwrightau]

nathans VY Calais - 'Calais 2.0'

Year: 2003
Odo: bought at 114,xxxkms, LS1 conversion at 143,xxxkms, motor at 70,xxxkms
Colour: Navy Blue
Engine: 2004 5.7Ltr LS1 V8
Brakes: DBA 4000 Slotted Rotors & Bendix Ultimate's all round
Transmission: 6sp Manual. T56 M12, GMM Ripshifter.
Exhaust: Pacemakers, Hi Flow Cats, Twin 2 1/2" Cat Back
Diff: 3.07 LSD
Electrics: Power Windows, Cruise Control, Climate Control, Full Electric Seats
Interior: Blue Leather Seats & Door Trims, HSV Steering Wheel & Airbag, VZ Steering Wheel Controls & Clock Spring, VZ R8 Binnacle Gauges
Wheels: Genuine 19" VY GTS, 245/35/19 Nexen rubber.
Stereo:
- JVC KW-XR810 Double Din, Bluetooth H/U
- JBL P660C 6 1/2" Splits Fronts
- JBL GT5-S265 6 1/2" Coaxial Rears
- JBL GTO 75.4 - 4ch Amp
- Option Audio OAK1200 Mono Amp
- JL Audio Twin 12" W3D4 Subs in a ported box tuned to 37hz
- KnuKonceptz 4GA Wiring

Mods

- V6 SSL Front, SSSL Rears KYB Shortened Struts & Shocks
- 35% / 18% Tint
- LED Lighting Conversion
- CREE LED Reverse Lights
- VZ Calais Tail Lights & Reflectors
- VY II Calais Side Skirts & Rear Bumperettes
- VY Calais HBD Front Lip
- D34 Yellow Top Deep Cycle Battery
- Hollandia Sunroof (Installed 03/11/12)
- Bootlip
- Mirrors, roof moulds and boot garnish colour coded

Plans

- Top mount blower

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/1277945_637628862956476_1877265545_o.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/823408_637629036289792_169391806_o.jpg

http://i.imgur.com/Ezz8Y.jpg

http://img.tapatalk.com/d/12/09/30/e9aqasej.jpg

Black upper interior conversion
http://img.tapatalk.com/d/13/02/13/jegeba5a.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/1234231_10200746680054264_657382480_n.jpg

http://img543.imageshack.us/img543/5405/img1714q.jpg

When I Got Her:

http://img190.imageshack.us/img190/1610/img1717an.jpg


Things that need fixing:
- Needs new wiper blades *done*
- Bonnet struts *done*
- Clean throttlebody *done*
- Drivers seat plastic broken *replaced*
- Shifter boot worn *replaced*
- Intermittent alternator fault *voltage regulator replaced, 115,XXXkms 30-1-12 *
- Idler pulley below the coil packs noisy *replaced*
- Change castor rod bushes *replaced*, 118,XXXkms 13-2-12
- Ashtray doesn't close properly *fixed*
- Glovebox droops down a bit on the left *fixed, replaced rubber stoppers & holding clips*
- Rear ashtray cover missing *replaced*
- Wiper jets and cover worn *replaced*
- Drivers door checkstrap worn *replaced*
- New genuine steering wheel controls 2/1/14

- Climate Control on HIGH occasionally the fan drops out
- 3/4 door speaker grills broken



Servicing, etc
- Engine oil & filter, transmission oil & filter, air filter 114,XXXkms - 20/12/11
- Mace manifold insulator & plenum spacer fitted, injectors recoed, plenum & throttlebody cleaned 116,XXXkms - 12/2/12
- Fuel filter & brake fluid changed 116,XXXkms - 13/2/12 (next brake fluid change, 13/2/14)
- Pacemakers fitted, plugs & leads changed at 117,XXXkms - 4/3/12
- Oil & filter changed 120,XXXkms - 7/4/12
- Wheel alignment 120,XXXkms - 21/4/12
- Oil, filter & rocker cover gaskets changed - 128,XXXkms - 21/7/12
- Transmission fluid flush - 128,XXXkms - 22/7/12
- Power steering rack changed at - 132,XXXkms - 4/9/12
- Wheels balanced at 132,XXXkms - 8/9/12
- Changed front rotors and pads at 132,XXXkms - 22/9/12
- Changed front passenger door actuator at 132,XXXkms - 22/9/12
- Oil & filter changed at 139,XXXkms - 15/12/12

LS1 Conversion at 143,XXXkms - 12/03/13
- Engine oil flush, oil & filter change at 70,XXXkms - 29/3/13
- Engine oil & filter change, Transmission oil and filter change at 80,XXXkms - 17/8/13
- OTR air filter cleaned & re oiled at 152,XXXkms / 87,XXXkms - 6/11/13
- Front wheel bearing hubs replaced at 152,XXXkms / 87,XXXkms - 8/11/13
- Engine oil & filter change, washer jet shroud replaced at 153,XXXkms / 88,XXXkms - 19/11/13
- Front rotors machined, rear rotors replaced & new pads all round at 153,XXXkms / 88,XXXkms - 22/11/13
- Manual conversion, new slave cylinder at 155,XXXkms / 90,000kms - 12/12/13
- Cabin filter installed at 158,XXXkms / 92,000kms - 27/12/13
- Handbrake shoes worn & bent, replaced with newer version that fixes scraping problem at 159,XXXkms / 93,000kms - 8/1/14

[nwrightau]

LS1 conversion

http://i.imgur.com/PUT5pY4.jpg

http://i1238.photobucket.com/albums/ff484/kudos_0743/Naths%20LS1%20Conversion/DSC_8107_zpsfc4c1b37.jpg

http://i1238.photobucket.com/albums/ff484/kudos_0743/Naths%20LS1%20Conversion/DSC_8109_zps76fa0093.jpg

http://i1238.photobucket.com/albums/ff484/kudos_0743/Naths%20LS1%20Conversion/DSC_8104_zps378d68ba.jpg

[nwrightau]

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1454603_10201288792246730_1028914027_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc3/1477596_10201264653883286_690342236_n.jpg

http://i.imgur.com/pkqkCTt.jpg


VZ HSV Steering wheel & VZ calais steering wheel controls (running vz clockspring)

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash3/1011567_10201387535195242_5699881_n.jpg


Added cabin filter

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1544508_10201408130550113_1699397149_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1545797_10201408133630190_1009393368_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1506762_10201408133070176_21742662_n.jpg


Skids at heathcote just before the master cylinder broke :(

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1601588_10201348960314968_405036591_n.jpg

[andrewslr]

You've built yourself a bit of a 'Frankenstein' there, but I really like it. Well done there grasshopper!

[nwrightau]

You've built yourself a bit of a 'Frankenstein' there, but I really like it. Well done there grasshopper!

Thanks mate! It's been a long but rewarding journey, at the very least you don't see many manual calais' getting around. I thought I was about to settle down for a while and save for boost... but then I went to the drags and now I just want to go again! First pass the master cylinder broke, didn't have a spare so had a lovely 2hr drive home with no clutch.

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/t1/1560763_630194107036368_1166058564_n.jpg

[nwrightau]

Fullboost wooo :)


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-frc1/1604532_10201530265403408_1640674661_n.jpg


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/t1/1526971_10201530265443409_597028693_n.jpg


https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/1512686_10201530265363407_982344415_n.jpg

[nwrightau]

:)

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-prn1/1016247_10201534554150624_1166838592_n.jpg

[nwrightau]

Turns out the clutch was in a very bad way. The gearbox is out at the moment, going to order a new clutch today - definitely something Tex, either XX Grip or Z Grip, leaning more towards XX Grip as it'll easily handle the power with a bit of added comfort.

[nwrightau]

added this to the gearbox

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc3/t1/1510816_10201603477833673_125389979_n.jpg


guess what's almost here :D


http://i.imgur.com/CanQU8g.png

[Stomper]

Car looks awesome mate.

great build.

the pro gear 70-75 is good stuff. run it in my clubby and made the box much smoother and less noisy

[nwrightau]

Car looks awesome mate.

great build.

the pro gear 70-75 is good stuff. run it in my clubby and made the box much smoother and less noisy


Cheers man, bit confusing topping it up though the box is out of the sitting on a bench at the moment. Drained the old oil out plus poured 4-5L of clean ATF through it to flush it out.

Added 5L of the pro gear and it's bang on the reverse sensor level, spilt bugger all. I've heard some of the VZ gearboxes have a slightly bigger oil capacity?

[Stomper]

Cheers man, bit confusing topping it up though the box is out of the sitting on a bench at the moment. Drained the old oil out plus poured 4-5L of clean ATF through it to flush it out.

Added 5L of the pro gear and it's bang on the reverse sensor level, spilt bugger all. I've heard some of the VZ gearboxes have a slightly bigger oil capacity?

not sure on the VZ's i think they run the same box so presume the same capacity.

[nwrightau]

YES!! Finally!
https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/t1/1601196_10201617193416554_752044750_n.jpg

[nwrightau]

Woooo! She lives again :D

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/v/t34/1545006_10201619919244698_1580250503_n.jpg?oh=dd06 d56c1978062e8a06b8d0cb77e35d&oe=52EDC67C&__gda__=1391302378_5516a4dd46625fcaf008bcb0ea9c460 4

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/v/t34/1450717_10201619919004692_184997134_n.jpg?oh=b56b2 561ffd299a6e99342063d194a0d&oe=52EDCD88&__gda__=1391338374_45535682468833c2a6127372767d6c8 2


Very impressed with the new clutch, pedal is much lighter and muccch easier going into gear - also the penrite oil helped with that box is heaps smoother :)

[nwrightau]

Bit of an update...


https://scontent-a-nrt.xx.fbcdn.net/hphotos-ash3/t1.0-9/1622814_10202244233132155_720958205348973293_n.jpg


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10253811_10202244233932175_8606041583345809301_n.j pg

GT42 arrived :)


https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/t1.0-9/10363817_10202304690523552_3293569842109179338_n.j pg


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http://i.imgur.com/3DKQ1Lw.jpg


http://i.imgur.com/YhkcPzv.jpg




Unwrapped manifold, as you can see the wastegate placement sucks and will be the wrong flange setup the new wastegate is vband. Weirdly, the gasket that came with the GT42 is T6 Flange same as the manifold, turbo is T4 Flange so that will have to be changed too.


http://i.imgur.com/rziutM1.jpg


http://i.imgur.com/YD88OdY.jpg


Relocated ECU to cabin, also moved throttle relaxer over a bit hopefully that will be enough to stop it getting cooked by the turbo.


https://scontent-a-nrt.xx.fbcdn.net/hphotos-frc3/t1.0-9/q71/s480x480/1491704_10202286987720993_8427151415653095832_n.jp g


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[nwrightau]

Wastegate arrived


http://i.imgur.com/7ke9qg3.jpg

[seedyrom]

Shit just got serious

[nwrightau]

Shit just got serious

No messing around here :D

[SirNemesis]

Still slow.... :)

[nwrightau]

Still slow.... :)


For now.... :D

[nwrightau]

Overflow bottle neck shortened


http://i.imgur.com/SdEBkcW.jpg


Oil adaptor arrived today


http://i.imgur.com/JIxjnKP.jpg


Intercooler brackets made and fitted


http://i.imgur.com/E4P6oNe.jpg


Front bar fitted with intercooler


http://i.imgur.com/rml4Ma5.jpg

[HSVX255]

good work mate, enjoyed reading this thread

[nwrightau]

good work mate, enjoyed reading this thread

cheers man, parts are slowly arriving. can't wait til it's all done!

[nwrightau]

lower control arms with new ball joints and bushes ready to go in.


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10383969_10202378308883965_2711379681832260950_n.j pg

[nwrightau]

Gauges installed

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10354224_10202494717074097_4645535817370308069_n.j pg

http://i.imgur.com/3ZzYAS1.jpg

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Passenger side manifold & crossover pipe done in a few coats of VHT. Gonna do 3 coats on everything final coat being black then heatwrap. Repco had VHT on special for like $9 a can so I don't care about the colour that much it's just an undercoat.

https://scontent-b-nrt.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10447645_10202481354660045_7241133885082953257_n.j pg

wrapping done, used the whole roll had to order more for the rest. Soooo much nicer to work with than the fibreglass stuff.

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10374966_10202488304913797_7945975910492046158_n.j pg

eboost 2 mounted in the flip up compartment.
https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10396289_10202501771730459_4308829570730963823_n.j pg

[andrewslr]

Really enjoying this build, well done. One question, would a jet-hot coat achieve the same result as wrapping?, would seem easier and probably look a tad cleaner.

[nwrightau]

Really enjoying this build, well done. One question, would a jet-hot coat achieve the same result as wrapping?, would seem easier and probably look a tad cleaner.

Thanks mate, getting close!!

Proper ceramic coating would almost certainly be better but at 3-4x the cost it's just not worth the money to me. $100-$150 gets everything in 2-3 coats of VHT and Titanium wrapped. This should keep the heat down a fair bit, ceramic coating is $600+

[nwrightau]

Updates

Everything painted in copious amounts of VHT and finished in black, wrapped in titanium DEI only the passenger manifold to go! Manifold is significantly better than the dogs breakfast pictured earlier in this thread.


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10509676_10202577409221349_3398119881327796655_n.j pg




heads off going to get machined tomorrow and new valve spring kit installed. arp head studs and ls9 head gaskets will be going on.


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lunati double valve springs installed


https://scontent-b-nrt.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10257451_10202589485883258_8774922121612965086_n.j pg

Such clean wow


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10427681_10202595574235463_3375008489103576267_n.j pg

Daaaat gasket ;)


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10494555_10202601845112231_8304403560785513665_n.j pg


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https://www.youtube.com/watch?v=HiaGesdWqL4&feature=youtu.be

[nwrightau]

Good to be terrorising the roads again.. :)


https://scontent-a-lax.xx.fbcdn.net/hphotos-xaf1/l/t1.0-9/10300240_10202617358860065_6387789330077062602_n.j pg

Extremely frustrating weekend not everything went to plan, but at the end of the day I look back at my car and how far it's come and just can't help but be happy about that.


https://scontent-a-nrt.xx.fbcdn.net/hphotos-xfa1/t1.0-9/10524322_759963380723023_4988983428357997230_n.jpg

[BigAnt]

Love the effort you have gone to and the attention to detail. Everything is mickey mouse. What gauges do you have installed in the binnacle? They look really good.

[nwrightau]

Love the effort you have gone to and the attention to detail. Everything is mickey mouse. What gauges do you have installed in the binnacle? They look really good.

Thanks mate :) they're some aftermarket gauges off ebay.

[nwrightau]

Well test fitted everything seems to fit nicely - except i'm not happy with the manifold to chassis clearance so probably have to get that fixed [bloody exhaust shop]. Apart from that, finally some decent progress!! Got a guy coming down tomorrow to work his wondrous welding skills on the intercooler piping :)




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[nwrightau]

Had a guy come down and work his welding wizardry on my intercooler piping. Big day but got it all tacked up with NO CUTS :D




*images taken on potato


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[offshore]

looking pretty good

[nwrightau]

These arrived today :)


http://i.imgur.com/Midc4rg.jpg

Test fit


https://scontent-a-nrt.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10494715_10202703891663331_2552939403851046664_n.j pg

[nwrightau]

Bit of an update


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpf1/t1.0-9/10341954_10202731286828193_5347563451858267569_n.j pg


Found a pod filter that fits, [5" inlet, not much space wasn't that many to choose from]. Also cooler piping has been welded up so that's all in - with no cuts to the car either.


Now i've relocated as many things out of the way as possible and i'm still not happy with the manifold clearance. It would be fine if you were willing to modify the cars body, or on a track car or something the manifold and dump setup would be great - but my vision for this is to be a reliable, powerful street car. So I'm selling all the current setup:


- T4 flanged turbo manifold, vband wastegate piping
- 4" vband into 3.5" > 3" dump pipe [gate piping plumbed into the dump pipe]
- Crossover pipe


I'm having a whole new setup made up by Gen Racing in adelaide, I've seen his work on a few mates cars and it's exceptional - loads of clearance and very well priced, steam pipe too.


So that should be about 2 weeks away, in the mean time I'm hoping to get my fuel system sorted. Surge tank made up, fittings ordered. Trying to find a space for the fuel regulator in the engine bay is proving to be a challenging task.

[nwrightau]

New manifolds, crossover, wastegate and dump pipe.


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10401576_10202855880102947_8235369622308603487_n.j pg?oh=8926940f70f584c0162d0b633980a342&oe=545CA894&__gda__=1415484353_b4271567accbb7dea878dfd340dd2c5 8


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Surge tank

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10509772_10202876798745900_6176095966746701171_n.j pg?oh=3c391fea6ad7ed8cfd3316aeb9cfeb5b&oe=54725FB0&__gda__=1416070310_d40e0c08d86d59359222d08a4c3f306 6

Coil packs mounted to covers


http://i.imgur.com/KBXrVn8.jpg


Elite engineering 2nd gen catch can arrived, it's damn sexy too.


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http://i.imgur.com/OtVAmTQ.jpg




Everything fitted up and bolts tightened :) Lots more trimming of the coil cover required to clear dump pipe. All leads in too, a little worried about the right rear one it's resting on the dump pipe a bit, all have titanium sleeves though so hopefully it will be right. Otherwise I guess that section of the dump pipe would need to get ovalled? or the coil pack moved back slightly.


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10569051_10202913300418419_2826273129043619071_n.j pg?oh=3ac6712f6ca9ee9d7c4a511c5166b259&oe=546C0F4B&__gda__=1417143598_2eacdf7e976038e9633b5d7a88b1280 5


Billet alloy clutch reservoir


https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10639613_10202913336659325_8341652359634506860_n.j pg


Oil feed line completed


https://scontent-a-sjc.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10357465_10202913333939257_2042472440525484897_n.j pg




The return line needs to be shortened by about half an inch which is annoying, god damn ptfe is such a bitch to work with. Also have a new alternator on the way, so if my current alternator was whining because it was shit that will solve it - if not it will at least rule it out and give me some peace of mind when taking the car to tassie in november.