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Helpful ReplyKnightrous' House of AW11 (and SW20, and ZZW30)

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RE: Knightrous' MZW11 & AW11 Saturday, September 23, 2017 1:48 AM (permalink)
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Me: 
I'm a little concerned with the exhaust near the axle cage boot. 
Knighto:
I have concerns as well. The exhaust is still to be wrapped to minimise heat radiation, but I do have a backup plan if it goes pear shaped. I will fit an ST184 supported equal length drive shaft on that side. It will shift the CV boot closer to the oil pump and a good distance away from all exhaust bits. I've been holding off doing this straight up as I am still running an S54 gearbox and it might explode before I get a chance to melt a CV boot :P 
 
You could just fit a shield with reflective tape then wrap the exhaust in that particular location. Will save a lot of time cleaning up grease. I have been there which is not he greatest way to spend your day..
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RE: Knightrous' MZW11 & AW11 Monday, September 25, 2017 4:30 AM (permalink)
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Fitted gaskets to the turbo and dump to reduce the exhaust leaks and found a massive leak where I forgot to fit the WB02 sensor (LOL!). When for a drive and we still have a sizeable leak, but it did sound a lot better. Will probably order some new gaskets and goop for the Y-Pipe next and see if that will fix the issue.
 
The budget has just taken a bit of a hit as I have decided to install a spare MS3X ecu, since it just simplifies a bunch of little things (ie: Water Injection control, AFR Safeguards and Knock Monitoring). Saves me having to play with these features in a WRX :P
 
Not MR2 related, but also helped do some welding for a friend's Toyota Starlet.



 
It was nice to take a small break from the MR2 and ticker on someone else's project.
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RE: Knightrous' MZW11 & AW11 Tuesday, October 17, 2017 2:33 AM (permalink)
+1 (1)
Another hit to the wallet as remaining budget is getting smaller...
 
An MSCN visit secured the parts to make the turbo feed line.


After originally putting the exhaust together, it had a pretty bad exhaust leak, which I assumed was coming from the flanges at the headers since they have no gaskets. Turns out someone just forgot to weld a flange up....
 

 

 
The Y-pipe was then wrapped in DEI Titanium heat wrap and fitted back on the car.


The additional loom arrived for the ECU as well, along with the dual channel knock module.

 
And finally, a cheap sandwich plate was purchased so I would have an easy to access oil feed port. I was going to use the oil pressure sender port on the block, but it is currently hidden behind the A/C compressor and is not a fun place to access.


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RE: Knightrous' MZW11 & AW11 Wednesday, October 18, 2017 11:48 PM (permalink)
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Fitted the 1/8NPT to AN-3 to the sandwich plate.

Turbo went back on.

 
Then made my 105cm turbo oil feed hose, and sheathed it with Fire Sleeve.

 
Sandwich plate fitted and hose routed.

 
And finally, installed a temporary pigeon filter. Final version will include a shielded air box and cold air being piped in from the bumper/wheel arch.

 
With luck, it will be spooling by Sunday.
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RE: Knightrous' MZW11 & AW11 Thursday, October 19, 2017 1:04 AM (permalink)
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Looks awesome!
Not sure if this has been covered but is there any risk of oil drain issues out of the turbo with it mounted so low compared to the oil pan?
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Re: Thursday, October 19, 2017 1:04 AM (permalink)
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Good work Aaron. Is this the mr2 you are using for WFP in Nov?

Sent from my SM-J320ZN using Tapatalk


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RE: Knightrous' MZW11 & AW11 Thursday, October 19, 2017 2:01 AM (permalink)
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Mrskylighter
Looks awesome!
Not sure if this has been covered but is there any risk of oil drain issues out of the turbo with it mounted so low compared to the oil pan?

Aaron will be installing a scavenge pump to help with the turbo oil drain. It's normal practice for rear/low-mount turbo setups.

There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
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Re: Thursday, October 19, 2017 5:43 AM (permalink)
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Mrskylighter
Looks awesome!
Not sure if this has been covered but is there any risk of oil drain issues out of the turbo with it mounted so low compared to the oil pan?

There is a scavenge pump installed in the boot that suck the oil from the return and pumps it back into the motor.

Carmikey
Good work Aaron. Is this the mr2 you are using for WFP in Nov?

I've got to finish the car, then get my entry in, so if the stars have aligned and there are still places left.... we will see :)
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Re: Monday, November 20, 2017 8:14 AM (permalink)
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So much #WIN

Mr Glengineering.
Please visit my other forums - 
www.celica.org.au
www.classic-ford.org
 
 
My build thread - https://www.mr2australia..m/mr2play/FindPost/47893
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Knightrous
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Re: Monday, June 24, 2019 3:43 AM (permalink)
+1 (1)
Hmmm, been a while since I updated this place, so lets blog this out.
 
The SW20 turbo wasn't finished for Wakefield. But ended up going to the drags.

 
The WRX had a clutch fail (centre cracked and let the springs out), ordered a new NPC unit.

Install was a breeze and it felt amazing.

Decided to do the brake rotors and pads.


About a month later, the gearbox developed some nasty noises. Inspection at ADS proved terminal.

Inspection of the rear diff was not positive either.


 
The SW20 continued doing it's thing, running nicely with the MS3X ecu and letting me tinker.

Decided to add an intercooler to the turbo plan after I found one in AW11 parts pile...

The brand new ($$$$) gearbox arrived for the WRX. Including a 20kg/mm center diff.  (TL;DR: Best 5 speed gearbox possible for a WRX).

And a brand new 4.44 rear LSD differential.

Someone then had a good go at wiping out the daily Subaru. But not good enough to write it off... $7600 of damage and they repaired it :(

Back to late night runs in the SW20 to gather data for tuning it.

Data, data, data!

The WRX comes back to life. New gearbox and diff are amazing, but a few other things are concerning.

For some reason it's using all of this gauge....

 
 
 
Decided on a refocus in life, returned the SW20 to stock and sold it. (Sorry, no bodgy 1MZ Turbo project. Just wait for the 3MZ AW11). Went to Japan for a holiday.

Saw the best AW11 ever.

Rented a boat in Japan.

Came home, decided to do some work on my AW11. Started the exhaust I always wanted to build.


WRX was making a lot of boost, 30PSI of it. Decided to fix that. Also decided to fix the suspension with a full replacement of bushes and fitment of Shockworks Coilovers (replacing the flogged out Cusco Zero2's)





 
It was really good after the upgrade, so we went to the Luddenham Raceway.

Some AW11 parts arrived.


Got a phone call, the engine place said this was ready.


Went on a holiday to QLD, found my race car. Might bring it home soon...

Made an executive decision that we needed a smaller car then the daily Impreza, something cheaper on fuel, more fun and easier to maintain. Bought an MX5.

Tested fitted the hektic JDM wheels from my AW11, looks awesome, pokes too much :(

Did some alloy welding for a mate doing some modifications to a 2ZZ.

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Re: Monday, June 24, 2019 4:12 AM (permalink)
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Good work Aaron, totally love the aw11 engine cover / lid what ever you call it.
Are you going to make any moulds?
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