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Vigo
Vigo UberDork
10/22/13 3:00 p.m.

So earlier in the month i was invited to tag along with GVX19 and m4ff3w to the challenge, but i was non-committal.

After a while i caught wind they weren't even set what car they were going to take but it was going to be one of their DDs. m4ff3w DDs a 1987 Shelby Lancer i traded to him and asked me what we could do to upgrade it for Challenge action. The gears were turning when i thought "Wait a second, why should we risk anyone's DD when i have ANOTHER lancer just sitting here and a pile of parts to throw at it? We can cruise to FL and blow it sky high and everyone can still get to work on monday!"

Thus began the current build.

I havent had this car all that long so i don't have much in the way of 'before' pictures. All i'd done to this car since getting it was add a better muffler to the full 3" exhaust and put the wheels from the Shelby Lancer onto the Lancer Shelby. I was courteous enough to do this BEFORE i traded the Shelby Lancer to m4ff3w so no theft was involved. There it is with the stock wheels. http://en.wikipedia.org/wiki/Dodge_Lancer#Lancer_Shelby

pinchvalve
pinchvalve UltimaDork
10/22/13 3:11 p.m.

I have a soft spot for that roof spoiler. Just thought it was way cool.

SilverFleet
SilverFleet SuperDork
10/22/13 3:15 p.m.

I'll be watching this one. I love those.

Vigo
Vigo UberDork
10/22/13 3:18 p.m.

A little back story on these lancers (mine and m4ff3ws): In june or july i made a package deal with my friend Bill to buy all his fwd-dodge related stuff for 2k. That included the 1987 Shelby Lancer, the 1988 Lancer Shelby, and piles and piles of stuff. Since then, i sold roughly $1400 worth of parts out of the parts piles and off of the cars so the budget is looking pretty good so far. I also traded the Shelby Lancer to m4ff3w for a 92 Montero which MAY end up towing us to the challenge. If that happens both the tow vehicle and the challenge car will be in the $2013 budget. If i sell the Montero before then i'll add that to the budget.

To kick the project off right we decided to completely replace the 2.2 engine and auto transmission with a better rebuilt 2.5 and rebuilt auto that came in the big dodge deal. We jumped right in on 10/14 'Genocide Day' and made good progress. New drivetrain pre-assembled and ready to go. M4ff3w's son was there to help out, as much as an 11y/o can be expected to. He has since turned 12 so we are looking forward to some improvement there (please excuse the horrendously messy background of this and all future images). Check out that sweet creeper. I broke it by falling onto it like a fatass about a million times. m4ff3w donated a slightly less broken one to the cause later. Turn's out having m4ff3w's son Demetrius take off the tires was a good idea because if it weren't for child labor it's possible one of us adults would have been exposed to this menace. The little bastard crawled into the caliper before i could humanely crush it, so we were forced to humanely burn it to death with lit brake cleaner. For the children.

mazdeuce
mazdeuce SuperDork
10/22/13 3:29 p.m.

You lit the car on fire. On purpose. I like this build already.

Vigo
Vigo UberDork
10/22/13 3:32 p.m.

I have found through many years of K-car ownership that the easy button for drivetrain swaps is to drop the engine and trans together straight out the bottom. Then, when it's on the ground, use the hoist to pick the car up high enough to slide it out, and then hook a chain to it and just pull. These K-car drivetrains have smooth bottoms and slide well on concrete. New motor+trans. A rebuilt, never-run 2.5L and a413 auto trans. I'll list the specs of these farther down. Did we clean the engine bay while the engine was out? No. The last motor had a horrible front main leak and the entire underside of the car is nasty. We'll get around to it... Slide the new one in and hoist it up! We had the new drivetrain hanging on the mounts before we stopped on 10/14. It took a solid 3 hours of work in the 4 hours we were there to get it that far. Gotta love K-cars... They're easier to swap the whole drivetrain on then they are to R&R a starter or a turbo on.

Vigo
Vigo UberDork
10/22/13 3:39 p.m.

During the week last week i piddled around hooking some stuff up in the engine bay. Even though you can basically put anything from any k-car into any other k-car, there is a lot of mixing and matching of slightly different bracketry to be done. I got together a small pile of stuff to clean up and was looking for a good way to get em clean without getting myself too dirty. First i thought "hey, how about that parts cleaner that's been sitting over there unused for so long that i dont remember anything about it!". Well, turned out the pump outlet was broke off flush and the pump didnt turn on, so... "Hey, how about that big old professional parts washer i took home from work a few months ago because they thought it was more broken than it was and i got it working?" No, that's sitting at a friend's house 30 miles away.

Ok, then, fine! If i can't use all the real tools i own, what about... an empty cat litter bucket... and.. the gas from the lawnmower, and... this... toilet brush sitting over here that i swear i've never seen before?! There are brackets in there. Im cleaning them. I own 2 parts washers and this is me cleaning some brackets.

turboswede
turboswede UltimaDork
10/22/13 3:39 p.m.

In reply to Vigo:

I used Harbor Freight furniture dolly's with simple wooden platforms to hold the drivetrains. Made them much easier to move around.

Vigo
Vigo UberDork
10/22/13 4:08 p.m.

BORING SPECS POST NO PICTURES

Engine: Rebuilt common block 2.5L

Unknown bore size and pistons

Rods assumed to be stock (only good for 4-500whp)

Stock or lightly ported (not sure) 782-casting cylinder head

2pc Intake manifold ported for 52mm throttle body (i put a smaller one back on it anyway) and maybe ported somewhere else, i dunno.

Aftermarket fuel rail for no good reason

Accufab adjustable base FPR

550cc Injectors

60trim or Super60 trim (not sure) t3 garrett turbo with stock turbine wheel, .48 a/r housing and tiny 2.25" outlet swingvalve housing.

2.25" downpipe immediately goes up to 3", followed by full 3" exhaust with one dynomax straight-through SS-mesh packed oval-case muffler out the back.

Modified FMIC from a Starion

Fidanza adjustable cam gear

Stock cam AFAIK

Stock in-tank fuel pump + external walbro255 in series

Trans: Rebuild a413 (3spd) clutch packs rebuilt with extra clutch disc and tight clearance

Stock valve body modified for line pressure and converted to full manual (no stuck governors, yay!)

Big-ish hayden trans cooler

Stock stall converter AFAIK

Suspension/Brakes:

Stock front brakes

Stock front swaybar

220 lb/in front springs (take that sensa-tracs!)

Stock rear springs, replacing with a thing we havent figured out yet

Stock rear axle w/drums is being replaced with a rear axle with biggest internal bar and 11" discs from Daytona CS (tip o' the hat to Mazdeuce for that one!) which will be boxed up with a plate welded to the bottom for more roll stiffness.

Gauges:

Matching Autometer Phantom Wideband, In-Cab Fuel Pressure, and 35psi boost gauge in custom plexi panel on center console.

Wheels/tires: 15x6.5 Shelby CSS wheels with 225/50/15 Kumho Ecsta AST. The tires are not very aggressive and too wide for the wheels but i doubt we want to spend real money on real tires. There is plenty of room in the budget to borrow some, however.

For the drags i have a pair of M&H 23/7.5/15 slicks on some light-ish 15x7 xxr 002s.

m4ff3w
m4ff3w UltraDork
10/22/13 4:15 p.m.

Yay! Build thread.

How'd you sneak a picture of me in there?

Vigo
Vigo UberDork
10/22/13 4:40 p.m.

I dont think i have ANY pictures with the mysterious GVX19 in them...

m4ff3w
m4ff3w UltraDork
10/22/13 4:52 p.m.

Sure we do, I shared them with you on Google+

mazdeuce
mazdeuce SuperDork
10/22/13 4:57 p.m.

I'm so damn happy that one of my parts is going to the challenge I can hardly stand it! That rear axle was supposed to go to the challenge in 2003. Better late than never.

Swank Force One
Swank Force One MegaDork
10/22/13 4:59 p.m.

What do you guys use to "control" bigger injectors on these cars? I know chipped/opensource ECUs exist, but on a GRM $2013 budget, do you just get as close as you can with the AFPR and call it good?

turboswede
turboswede UltimaDork
10/22/13 5:12 p.m.

You can program your own ECU fairly easily, if you're comfortable with it.

Otherwise, yeah some use larger injectors with an AFPR and let the ECU control things as best as it can until you reach WOT, when the ECU just goes nuts and dumps fuel.

There have been people who've used stock or nearly stock injectors and merely added cold-start injectors to come on via solenoids controlled by pressure switches.

Swank Force One
Swank Force One MegaDork
10/22/13 5:18 p.m.
turboswede wrote: You can program your own ECU fairly easily, if you're comfortable with it. Otherwise, yeah some use larger injectors with an AFPR and let the ECU control things as best as it can until you reach WOT, when the ECU just goes nuts and dumps fuel. There have been people who've used stock or nearly stock injectors and merely added cold-start injectors to come on via solenoids controlled by pressure switches.

Heh, a la Greddy Rebic or HKS AIC.

"We" do that too, but it's not so common anymore.

Was just curious what's out there on the cheap. These cars are always interesting to me how they can somehow make as much power as they do.

moparman76_69
moparman76_69 Dork
10/22/13 6:15 p.m.

The factory computer is completely unlocked at this point. It doesn't make any sense to use map bleeds, RRRs, and cold starts anymore. Either socket a computer or even buying one is budget friendly these days. Buy a willem burner and download the free tuning software, then don't blow it up.

Vigo
Vigo UberDork
10/22/13 6:19 p.m.

If i can buy a 3-bar map sensor i can DIY a calibration that is scaled for 550cc injectors and the 3-bar map sensor so i'll actually have fuel and timing control up to 29 psi. I already have socketed ECUs and a chip burner.

But i need to get that map sensor. Otherwise the computer stops adjusting at 15 psi and by 18-20 things are really out of whack on pump gas.

With this turbo and intercooler, 300whp is really pushing it. I doubt we will get that close on a last-minute DIY cal. But to get anywhere close with this setup we'll need to go over 20 psi so that 3-bar map and re-scaled calibration is pretty much essential.

Vigo
Vigo UberDork
10/22/13 6:23 p.m.

So the starion intercooler really isn't bad... unless you count the ridiculously tiny pipes coming off of it.

I chopped the pipes off and m4ff3w worked it with a dremel to get the end tanks opened up for 2.5" pipe. That's about all there's room for! This is where the mapp gas and HF alumaweld sticks come in.. to be continued!

I've got it mounted to the front bumper support which was nice and easy but it's actually making life a little harder right now since i have to have the bumper support on to mock up plumbing and the bumper cover and fog lights and turn sinals and lower lip are still attached to the support.

tb
tb Reader
10/22/13 8:25 p.m.

Another turbo dodge...Excellent! I fondly remember my turbo dodge days and always wanted to pick up a lancer at some point to get back into them. Yours looks very clean and complete; looking forward to checking it out at the Challenge.

I myself only decided to enter a couple of weeks ago but somehow I think that you will accomplish more than I will in the next month...

tb
tb Reader
10/22/13 8:27 p.m.
mazdeuce wrote: I'm so damn happy that one of my parts is going to the challenge I can hardly stand it! That rear axle was supposed to go to the challenge in 2003. Better late than never.

I almost giggled like a school girl when I found out that parts from one of my old Daytona Shelby Zs were on Pat's SCaries!

He has made better use of them than I ever did, but it is funny how small and incestuous this world can be.

Vigo
Vigo UberDork
10/22/13 9:24 p.m.

This car is pretty decent but it does have one ugly quarter panel which may or may not get fixed before the challenge.

Here we have a super custom gauge panel for boost, fuel pressure, and wideband. It will be painted opaque at some point. And, you know, the gauges will be hooked up. Trans cooler and the hole we opened up to run charge piping. Supposedly 2 2.5" pipes will go through there. It's gonna be tight.. There's the intercooler mounted to the bumper support. I put it all back on the car and stared at it and i think i need to flip the intercooler and move it up a bit. Should just be drilling two more holes to make our charge plumbing a lot easier. Gratuitous shot of engine. Wish that AC compressor and lines would paint themselves but oh well.

tuna55
tuna55 PowerDork
10/22/13 9:50 p.m.

Cool!

sethmeister4
sethmeister4 Dork
10/22/13 11:18 p.m.

Very cool! This car is so ugly it's cool! Good luck at the Challenge!

Vigo
Vigo UberDork
10/23/13 5:56 p.m.

I actually think the car itself is good looking once you lower it and put the right kind of wheel on it (wheels cost $$ so im not putting them on this car for the challenge).

Here's one with better wheel offset.

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