Jaffas 2.5 classic Strip and Build

[2-jaffacake-tone]

For a while now i have watched my oil pressure drop(well that my excuse to the misses)

After driving a 2.5 in a classic couldnt get over how much torque is had and how fun it was.(460/450)

so i just purchursed a Ej257 block and some sti3 heads/cams
my goal is 450/450
md321t turbo witch is a bolt on turbo.
i will be uprating rods/pistions ect i will over spec just incase i want more in the future.
will keep you updated how it gos with some pics.

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so far i have 740cc incectors
apexi power fc
rodger clark uprated oil pump
rodger clark light weight pullys
defi gadges
innovate lc-1 wide band
sx fuel pressure reg

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striped engine down yestoday.all seems fine nothing out of the ordinary .
new water pump,cambelt tensioner.inlet manafold (to play with) and RCM oil pump turned up today was like christmas

next thing is to strip the heads and and check valve guides etc, then send them away for gasflowing

will get some pics up v-soon

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camra is on charge next to my car keys so i wont forget to take it in.
tomorro

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A very messy engine bay removing old gauges. also removed air con as well.


i have fabricated my knock link in my air duct.


wires and bits every where at the moment.
avcr in wired in to the ecu wireing.



cleaned engine ready for build.

bottom




i have been speaking to mark @ lateral performance about my spec, possibly might get the 2.5 relinered to make it even stronger so i can see over the 500 mark in the future.

waiting for prices...

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right i have a twisted turbo kit sorted. just got to spec it to what up pipe size and wastgate size which i dont know:2ponder: i think 44mm wastgate.
hope to be running a gt35r. so dont know on up pipe size:2ponder:
i have recived more braided line to carry out the parallel fuel mod.i also have received the rest of the timing belt gear 3 more guide pullys.

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also in pic thermo inlet manafold spacers. these will lift the manafold higher so i can squeze the turbo pipe underneath the inlet manafold and will stop heat soak into the manafold as well.

[2-jaffacake-tone]

Originally Posted by 2-jaffacake-tone

these will lift the manafold higher so i can squeze the turbo pipe underneath the inlet manafold

didnt say what pipe is going under the inlet manfold.



somthink like this

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big thanks to wayne for my manaflold.
dont think he is going to do any more due to the 16hrs it takes pic dont do it justice.

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A few more bits in the bedroom now
had a slight issuse with scooby clinic with headers i bought off them but i came out of it quite well





also got kevlar timing belt from the clinic



also some bling billet fuel rails got them off fleabay very cheep as someone had bought them for the wrong year car


and still waiting on swirl pot. and a few other supporting mods.:thumb:

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hi nige i am changing all tensioners and guide pulley as a precaution as well as the water pump. the ones on my 2.5 were ok no play not nosiy but not worth the risk.
as for head gaskets going for 1.6mm and been told to aim for 8.35:1 compression ratio

i am going for 1-5 ppg straight cut box and a OS Giken twin plate clutch (comes with its own flywheel)

aiming for the 500 mark but anythink over 450/450 with quick spool is my main aim.


my next steps will be sorting my sti heads out new valves/springs/retaners/ and port and polished/ shimed up. going for dh22 cams and rcm pullys

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just purchased some cusco coilovers, think they may be very hard but will give them a go.

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still buying parts dam rcm website should of gone out drinking:squint:

WRC Titanium Valve Spring Retainers
set of Uprated Valve Springs
changed injectors to some 740cc witch have been flow matched by lateral to 800cc aslo have got samco inlet pipe and k&N filter fot the gt35 its 4inchs internal diameter. also got a power steering reservoir relocation kit.

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more parts ordered today from rcm should soon have enough to start the build.

so i got
RCM Alloy/Steel Vernier Pulleys
1.6 Steel Head Gaskets.
14mm WRC Up-rated Head Stud Kit
RCM 14mm WRC Head Dowel (x4)
acl main bearings
acl bigend berings

just over 1500quid before breakfast

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this is a vf24 turbo compered to the inlet hose of a gt35r should be big enough

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saturday i had a easyish day so i thought i would strip my heads and get them cleaned up ready for gas flowing ,bigger valves and the the head bolt holes machined to take the bigger head studs and dowls.

heads complete






remove cams



pull out bucket (see shim underneth)



compress valve spring remove collets unspring gently else you spend hrs looking for the lost collets



this it the vavle the valve spring the sping retainer and the 2 collets



repeat 16 times lol then washed them in the wash tank

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so bit of an update with a few pics of some goodies which arived this morning

pas relocation kit



Alloy/Steel Vernier Pulley Set



14mm/14mm headbolts maybe a tad over kill? will dowls




Set Of 16 WRC Titanium Valve Spring Retainers
Set Of 16 Uprated Valve Springs





head gaskets/acl main bearings/big end bearings

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right from monday i have a week off work, i also have brad down helping me, we plan on striping the inside out ready for the roll cage to be fitted, witch i hope turns up this week. not sure wether to run the car with carpets etc or to strip it out. the cage is a 6 point omp bolt in jobbie so still can retain the rear seats if i want.

also may even open the bonet and remove stuff ie engine.

also now looking a hydra ecu comes with mafles set up /knock control/anti lag/lanch control and seem to be a very good price. just dont know any one useing one

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the weather is getting nice now so i can have a few evenings in the sun with it hope the roll cage turns up this week so the bodyshop can get it painted.

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its like xmas most days lol

so today me and brad started striping the inside out ready for the cage to turn up, as we were distroying my car it arrived
most of the problems were down to my alarm systum, due to a very good install(too good:susp. but other than that wasnt too bad.

i have been thinking for the last few weeks weather to have it striped or full interior. after removing a few things today ,I have decided to strip right out. so i have aranged with the body shop soon as i have striped fully and welded cage mounts and removed sound proofing, the inside is going to be paited in 406 silver with a bright blue cage

so while brad was cutting lots of wires i was chiping off sound deadaning, witch is a crap job:squint:

few pics

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an update from todays effort stripped more!! and removed more sound crap!!!
i got the cage back in to start a dummy run to see where i need to weld the brackets.




front bracket


rear bracket.

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its booked in on the 23rd at the bodyshop for them to work there magic. i booked the day off to help them if needed

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i booked thursday off to help fitment of cage in bodyshop, but they are running behind so now in monday
as i had the day off i attacked the last of the sound deaderning, then started to wipe down inside to get the gule/yucky stuff off useing thiners(not a good idea! car was in the sun i am kneeing on the floor with doors shut i passed out 2 times before i could manage to open the door,when i got out i was high as a kite.

a couple of pics how it looks..

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car went to the bodyshop today we are modifying the brackets as they done fit that well imo.
will get some pics up of that up soon.


as i am doing away with the A/C i have removed the a/c matrix witch is quite heavy! also blocked up holes useing soldering iron.
this is the unit


taken apart


back togeter with holes


then filled in


on the mission to remove as much weight as poss

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Body shop has finished for now the brackets are all welded in.
rear bracket tacked and drilled


welded rear


center


front


i managed to get the dash support bar back in and the dash back on ready for cutting hopfully i will do a neat job:squint:


when the cage fits around the dash i will send it away to be flocked. and back to the bodyshop for some paint

[2-jaffacake-tone]

i have cut the dash it hasnt come out too bad

i made a bit of roll cage up as a dummy to help mark where i need to cut.
the white marks are tipex so i know where to trim.

I did speck to dyney about a spare just incase:haha:











also have a few more things arive
oil modine
cool running thermosat
goodrigde fittings (stupily expensive by the way!!!!)
044 fuel pump
swirl pot
steering wheel+boss

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been a while since i updated this, so i met a guy in a carpark gave him my brand new headers and my full systum exhaust and some money, apranently he is going to make me up a twisted turbo set up for me lol(he will and i am very sure of it) just a bit strange handing over all the stuff not knowing him apart from a few PMs lol. i am having a twisted turbo set up to take the GT35/40 T3 flanges also having a screamer pipe off the exturnal wastgate but also a small link pipe made to fit back to the down pipe if its too noisey.

The roll cage is in primer the car is on stands wheels are being refurbed and painted the same colour as the cage hopfully this week.
i am on holiday as of next week. i plan to finish cleaning uderseal off carry out seam welding and start to prep the inside for paint(colour unknow) poss audi white?? its in for the inside to be painted on the 20th i think. the dash is ready to be sent away to be flocked just need to wrap up and arrange for collection..

i am currently saving up for a few big things turbo,clutch,gearbox.

engine displacemant is still unknown. was going for the ej257 but wont be strong enought for my needs and future goals. i know i am still useing sti3/4 gaflowed heads with dh22 cams and rcm pullys. i will choose engine cc/ type last thing as i dont want an epensive engine laying about collecting dust.

hopfully have some pics for seam welding, colourfull wheels and cage soon

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started the seam welding hopfully will be painted this time nex week!wheels are in primer

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wheels

cage in oven ready for paint

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no comment steve lol would like to aim for the next ring trip

roll cage painted

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a pair of these should turn up tomorrow
http://http://www.driftworks.com/cat...7fa15ff2dde4b6

also a solution to a problem witch has been buging me. the roll cage goes throu the dash and out throu the bottom there the bonnet relese goes , so i have bought these (locking of course)
http://www.driftworks.com/catalog/produ ... -pins.html

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pic of the wheels from the right side.


turbo kit nearly done. sitting on the up pipe is my gt35/40r turbo



i have also brought a tial 44mm external wastegate

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been spending again
Lateral Performance high capacity big wing sump, with RCMS catch can, oil cooler with pipes and take off and Forge Alloy strut brace to hold the catch can.

Sump has been modified so it has a port for a temperature probe, and also has a -10 male for the catch can return. Sump, together with oil cooler holds about 7.5l

Catch can has been modfied to have a -10 male for the return to the sump (-8 as standard) and goes through braided lines to the sump via an Earls one way flapper valve which stops oil flowing back up into the catch can.Hoses have also been fire sleeved.
Forge alloy strut brace, which has a boss welded on to hold the catch can, so the can sits up nice and high.

1200 notes

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finished the seam welding today will be in the bodyshop next week for paint:thumb:

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right as normal things dont go to plan... was due in for paint last week, then we decided on some mods to the boot floor. witch is in the prosses of being cut out and doing a flat boot conversion. will have some pics on wednesday

the idea of this is to lose some weight, easer to mount fuel set up on a flat floot

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pics of the boot being cut out, no turning back now

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still on it

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few more of tonights work..


inner wheel arch is now atached to the chassis leg


rear pannel cut away


ally angle piece for the new floor to sit on


started to make a template

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the boot floor will remain flat. i have been thinking about having a defuser like the zen car, just not sure about the exhaust as most of the cars who have a big ally defuser run front mount turbo set up

started to strip the engine bay got rid of the abs unit, also started to dummy up for the rotated inlet manafold, moving the aulternator to one side etc


also a pic of my seat belts

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he was well supervised should have some more pics mid week hopfully with a flat boot.
looking at battry recolation kits

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just brought a 6 speed gearbox very very good price

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not even sure if it has dccd

the solaris s6 cant drive it directly its needs a high current driver = small little circuit, if i wanted just to open the diff i could just wire it to the handbrake switch ie 1 click on the hand brake opens the diff witch would be ideal for manovering or wire it into the origianal controller. once set up i dont see why the dccd cant be controled by the CAL switch useing tps and vehicle speed ie turn switch to number 6(tecos carpark mode)

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6 speed box next to a 5 speed. box has come out of an MY05 STI
NOT dccd but cant complane for the money i paid:squint:


template has been made and been copied into the compusite alloy.

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iam in no rush, trying to do it with out owing any money to the bank so once built iam not still paying for it 4 yrs later.

this weekend i will mount the 6 speed in and make sure it clears,some people say you have to fetttle the tunnel others say they fit ok,so i thought before it gets painted inside i will do a dummp up.

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no credit cards this project is being paid as i go i got my credit card sitting next to me with a 8 or 9k limit but not touching it.

cheers for the heads up on the prop found someware i can get them for £100 and i need 2 so hoping he might do a deal


6speed=sooooo heavy
I have fitted the 6 speed as a dummy run, . i didnt want the inside to be painted and then have to attack the tunnel with a hammer
It fits!! its a bit tight

have some pics will put up later

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will get some better pics of box(done on phone in the dark)


powersteering relocation kit done


also carldavey thottle body wedge is being welded on my shiney manafold

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floor is in its not staying red thats the colour it came in..






also started cutting the loom about getting rid of anythink not needed:

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lol steve not alot

cut away the rear parcel shelf as its being covered in ally


also took some weight out of the boot lid

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i have these for the boot going to have these on the top corners and make up a drop the boot in and on sort of systum

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The rear sceen is out now as it willl be easyer to cut out and make template for the ally parcel shelf/firewall, also there was some rust coming throu around the window so this can now be preped :

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started to make alloy parcel shelf/fire wall

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few more

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thought i better bring this back to life
done a dummy run to check to see if the new brakes go under the wheels, they do JUST!!
thinking of getting the calipars painted? bearing in mind the car is going to be white what colour??

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heres my baffled sump and large oil cooler
sump holds 7.5ls

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Thanks dude
found my gauges today, witch i brought a year or two ago and missplaced them:squint:




Today i removed fuel pump assembly. to fabricate to fit -6 lines to swirl pot a few pics hope to get them braised on tomorrow
what i used were not ideal so i had a bit of cutting and drilling to be more suited

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brazied ends on today


and painted


and reasembeled with a walbro255

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turbo turned up today



Also i have removed the wireing loom so i can strip down all the wires i dont need abs,radio,central locking,key coding,alarm,+various other rubish i dont need.




Chat about the build here: Jaffas 2.5 classic

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got my dash back from being flocked done a quick dummy up.



the end of next week the car is going away for the underside to be shotblasted and painted

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been very busy this week so after work tonight we striped the engine, suspension,petrol tank, doors ect as its going away tomorrow to be sand blasted to remove all the under sealer







also have subframes blasted aswell, so striped these down ready

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its at the worst point at the mo, so evreythink from now on will be assembling and putting it back together, should have it back in a week

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got tyres


also went up to the blasters today to cut the front screen out, iam now looking at getting a heated front windsrceen so i can do away with heater vents/motor/matrix/box and wireing .

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got my block now its a 2.0 closed deck block linered to a 2.5



an a set of wiseco pistons

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Picked the shell up this weekend, to say i was unhappy with the result was an understatment, they couldnt remove the undersealer all over as planed, the parts they did remove they primed, 3 of us today started the massive job of scrapping the undersealer and prepping by hand

[2-jaffacake-tone]

also i have now sorted fuel pump plate an made some neat holes.


still playing about with the custom wiring loom iam removing all the unnecessary wires (i hope it all still works its not my strong point
no radio,heaters,elecric windows,mirrors,central locking interior light abs aircon,airbags etc

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back off my holiday
When i was away my suspension bushes turned up.so iv started to re-bush.
done things the wrong way round really should off removed the old bushes before i got the units painted having to be very carfull

my plan

drill out center



then run a hacksaw throu the outer sleave

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now finished the firewall








Slight change of plan with the converting to windey windows
going for somthink lighter

rear


front drivers side


perpex The windows will be up all the time, i have a little sliding window hatch for the drivers side.


hopfully should be getting my fiberglass doors very soon as there are now ready


my block is away at the moment havinging some work done on it.

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Thanks guys. Still cutting bits out of the shell! The inside and bay are being preped next week ,hopefully painted the week after I hope .

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Lmao sorry dyney

picked up inlet manafold witch has had wedge welded on

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cheers mate.

still cutting more weight out of the shell



started to clean up throttle body wedge



got my block back form being decked , my clyinder heads have gone away to be crack checked,new vavle guides an gas flowed an bigger valves to be machined in.

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finished porting the inlet manafold now, the heads are away being gasflowed at the moment also having bronze valve guides fitted, larger valves, 3 angle seats, also having shimless buckets made up also the combustion chamber is being machined to suit a 2.5

got by block back from being decked only needed 4/5 thou off to make it flat .

the rear panel is almost done,

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Right well the engine bay,inside an boot have been painted, hopfully the v8 mx5 will be coming off the back ramp so i can assemble my suspension

Iv brought conrods an a set of lumpy cams the only thing stopping the engine being built is a crank an head bolts .

will get some pics of the painted shell tomoz










a checky pic of inside boot will get more when the car is out of the booth

[2-jaffacake-tone]

Originally Posted by BIG"E"

looking good Tone


You've still got 8 months 3 weeks to finish.

better pull my finger out then

just trying to find where i put all the bolts lmao

A few pics, the mazda is on its wheels so i have nicked the ramp, didnt attened jap bash as i wanted to get a few hrs on mine

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Started to throw the car back together,
iv brought some suspension stuff
perrin 25mm rear anti roll bar an 22mm front + links bushes etc iv also got adjustable latreal rear links, iam now on the hunt for some coil overs.

so far the pedle box an servo are back on the dash bar is in. ive made the front brake pipes up, the petrol tank is painted an in and rear subframe,diff support bar is in wont be long an it on its wheels

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got a bit more done (one armed)
will get some more pics up

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Thanks andy,slowly getting there now, iam quite enjoying putting it back together.

finished putting cage in today,an dashboard, waiting for a few suspension parts to arive

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done a little today, droped old engine in and fitted turbo set up for a dummy run + iv got to make some IC piping re-bushed front arms and had a sort out of fuel bits
also sorted out a R180 rear diff and a set of bc coilovers

[2-jaffacake-tone]

Originally Posted by Nige

Can I have a drive please?

yes mate, iam not getting in with you thou lol, i will try and keep up behind in yours
iv managed to sort a 6-speed propshaft, a trip to craigs an picked up a few clips an more inportantly one of these lower arm brakets i need just need one more (see wanted thread) http://www.southeastscoobies.co.uk/v...ead.php?t=5997

few pics from todays 1 armed atemps
fitted the front antirollbar, had to adapt the D-bush clamps but its on, started to make the rear brake pipes up but still waiting on a manual compensator valve.

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managed to get some super rare rear hubs tonight been looking for a while classic R180 off a v5 type R (not meny people breaking them.
Diff should be here tomorrow, prop shaft turned up today as did more fuel fittings, iv got a 6 speed gear selector ,just got to finish off the rear suspension and it will be back on its wheels, iv finished the rear brake lines, gearbox should be in tomoz

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cheere guys


Finished putting the front coilovers on, had a slight problem with my local subaru dealer, the fact that they cant be arsed to do anythink! ended up an phoned another who were very helpfull so i have now sorted my 6 speeed selector out, The gearbox is ready to go in now

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rear hubs turned up this afternoon,so iv striped them down,burned out lower bush cleaned an painted and pressed in new bush, and fitted on car:

And finally its sitting on its wheels 2 days ahead of schedule.

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thanks steve

had some issues with the 6-speed selector and clearences but i think iv sorted it now., also managed to finished the brake lines inc the proportioning valve, got all the fuel ends now so loads to be gettting on with this weekend

hopfully this sunday iam going up to pick by fiberglass doors

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Finished the in car fueling, just got to clip down the lines

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started to make a new bumber support bar an make rear exhaust hanger,iv also started working on quick release boot.





iv spoke to the guy who made this,Might be making one for me. what you recon?

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cheers dunc will look in to that, maybe a side exit would be easier


The doors are completly bare no bolt holes for hinges catchs, handle, so iv started cutting doors about

the edges still need triming, the body shop will be doing that.

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It moves (not powered by engine lol),its now off the ramp an went away for some alloy welding at my friends workshop




finished modding the IC

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finished cliping down the fuel lines, also started mounting the doors

[ralliart didz]

have you finished this yet tone

[Hongkongfooi]

Originally Posted by ralliart didz

have you finished this yet tone