ClioSport.net

Register a free account today to become a member!
Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members through your own private inbox!

MR2 K-swap Project



dann2707

ClioSport Club Member
Well I thought the engine looked like an engine before earlier up in the thread but now it definitely looks like an engine that's for sure.

I've fitted a lot of the ancillaries, inlet manifold that's now silver silver. New gaskets and fitted the throttle body and adapter plate I bought earlier in the week.

It's pretty much there now and I'm so happy with it.

Random pictures in a random order as always

Removed a lot of the crap from the aluminium faces with a drill and wire wheel which might be in one of the photos. Your guess is as good as mine.



IMG_20191003_174705.jpg
IMG_20191003_194244.jpg
IMG_20191003_214512.jpg
IMG_20191003_193455.jpg
 

Rojer

ClioSport Club Member
  Civic
Doing a great job on the refresh, did you change the oil pump? A good upgrade is the fd2 one :)
 

JB21

ClioSport Club Member
@dann2707 have you pulled the 1zz out yet? Getting a start on mine soon but by the looks of it they can only come out from underneath.

Was going to use the below video for reference.

 
  MR2 Mk3 / Giulietta
@dann2707 have you pulled the 1zz out yet? Getting a start on mine soon but by the looks of it they can only come out from underneath.

Was going to use the below video for reference.

@JB21 they drop out from the bottom. You can undo the struts and brakes and drop out the whole thing - then lift the car up and pull the suspension and engine out with the subframe.
 

JB21

ClioSport Club Member
@JB21 they drop out from the bottom. You can undo the struts and brakes and drop out the whole thing - then lift the car up and pull the suspension and engine out with the subframe.
Cheers mate. Just refit in reverse with subframe attached or get the engine in first and attach subframe after?
 
  MR2 Mk3 / Giulietta
Cheers mate. Just refit in reverse with subframe attached or get the engine in first and attach subframe after?
Engine first 👍🏻Dont forget the lower and upper 2 engine mounts when you drop it
 

dann2707

ClioSport Club Member
I've got a bit of spare time now so I'll update.

So basically, I will be making my own exhaust manifold and exhaust for this project as I want to give it a shot myself.

I was going to be buying an exhaust modelling kit from America called icengineworks however its very expensive, it comes to £450 for the kit I'd need delivered including tax.

Screenshot_20190921_193403_com.android.chrome.jpg


The kit allows you to pre make the manifold to the correct length and do all your routes before f**king it up 30000 times if you didn't have the kit. The blocks click together like lego and you then, with the use of an additional plate, allows you to cut exactly where the mould was to mimic your exhaust in stainless.

I have my mandrel bends and flange ready

IMG_20191007_184523.jpg

IMG_20190925_212201.jpg


The huge downside to the pre made kit is the fact that it comes in thr wrong centre line radius bends. It comes as 2 inch, 3, 5 and 6 which is not what is readily available in the UK (we get 1D and 1.5D bends very easy)
So even if I'd mocked it up the radius would be wrong anyway

So... What should I do? Print and build my own kit 😁😁😁😁😁 bought the printer on Sunday and have made some good progress already. Its cheap as hell for the plastic so works out significantly cheaper and I get a 3d printer at the end of it all.
Ice already seen you can print off a 3d clutch alignment tool for the K20. Mint

IMG_20191007_180816.jpg


Few trial runs

IMG_20191007_213107.jpg

IMG_20191010_003236.jpg
IMG_20191007_180816.jpg
IMG_20191009_173811.jpg
IMG_20191009_173843.jpg
IMG_20191007_213107.jpg
IMG_20191009_065714.jpg
IMG_20191010_065801.jpg



This means I can also print the larger models when I do the bigger exhaust bore.


Massive thanks to @Louis for designing it and sending it through! I've got cad so can tweak and print as necessary.
I'll be printing the 4 to 1 merge collector too for the mockup stage.
 
Last edited:

dann2707

ClioSport Club Member
Absolute shed loads of parts printed and I've been working on some other models to help with:

Aligning the metal for cutting
Tack welding the tube together
Holding the pieces whilst cutting.

I'll post photos when they're done.

Well chuffed with the machine and I'm enjoying the design and editing side of it so much

Last night I printed off inserts that go into the flange. The bit behind the flange is wider so it holds it against the engine securely whilst I mock it up.

I've ordered all the y pieces I need, I'll be making it a 4 2 1 design based on a model that gives good power for the type r's

IMG_20191014_233026.jpg
IMG_20191014_232243.jpg
IMG_20191014_232247.jpg
 

David Stuart

ClioSport Club Member
Exhaust is a nice touch for this project. I love a bit of welding as well and exhausts are much more forgiving than body panels.

Are you making it from stainless? What welder are you using? Mig or Tig?


Sent from my iPhone using Tapatalk
 

dann2707

ClioSport Club Member
Fuckin clever b*****d
I can't take all credit for it as the system exists (just in a s**t form and needed massive improvements) cheers though mate
Exhaust is a nice touch for this project. I love a bit of welding as well and exhausts are much more forgiving than body panels.

Are you making it from stainless? What welder are you using? Mig or Tig?


Sent from my iPhone using Tapatalk
Thanks buddy, yeah it will all be in 304 stainless and fully tig welded.

I will be making some back purging caps for the argon too so that the weld is nice and strong on the inside.

I have an r tech ac/dc tig 210amp digital. Its a beast and way over specced for what I use but it's future proofed I guess. I'll be welding with a max of 40 amps for this as it's 1.5mm thick.

Also disclaimer I have never done anything like this before so I'm going to come across some road blocks but it's how I deal with it is the true learning and development on a project like this.
 

dann2707

ClioSport Club Member
Fitted the new bits and pieces to the printer last night and its so f**king quiet now it's amazing. The fans are gonna be changed tonight too.

Overnight I printed the work piece that will hold the mandrel bend in whilst I cut it. I included captive nut holes and shaped it so m6 cap head bolts nicely sit in flush.

Grips it perfectly and will help to get nice clean and precise cuts on the horizontal band saw.

IMG_20191016_071312.jpg
IMG_20191016_071332.jpg


*disclaimer the bolt isn't pushed in on that pic
 

105e

ClioSport Club Member
  phase 1 flamer 172
Do the parts mountings, d/shafts etc have to come from the good old USA, im not aware of any more local stockists. thanks
 

bashracing

ClioSport Club Member
  1993 micra
Berrisford will make custom shafts for anything, no need to pay import tax on them

 

R3k1355

ClioSport Club Member
This is pretty awesome.

How much have you got into the pipes and joiners and stuff? Excluding the printer
 

dann2707

ClioSport Club Member
This is pretty awesome.

How much have you got into the pipes and joiners and stuff? Excluding the printer
The plastic or the metal?

The printer came with 1kg of plastic and I'm about 1/4 of the way into that. I bought the grey which I'm about 3/4 of the way in. That was £14

The metal, 4 x bandrel bends was £35
Flange was £35
V band was £16
Y pieces x 3 were £30 total
3 to 2.5inch pipe was £10

Im currently printing off some tig welding back purge cups for the actual welding of it. @jaff. take note 👀👀

Printed off some antivibration feet for them to use with squash balls and it's made a huge difference. Man this thing is f**king sick.

IMG_20191018_190648.jpg
 

dann2707

ClioSport Club Member
The peen is finally in the garage.

I've started removing bits and bobs such as the rear bumper, lights, airbox, battery and some trim/bracing.

IMG_20191021_190332.jpg
IMG_20191023_183550.jpg
IMG_20191023_185235.jpg
IMG_20191023_190652.jpg




I've also started welding some of the exhaust where I can, started on the V band to the 2.5 to 3" adapter. This is my first go at welding stainless and I gotta say i'm impressed with how it's turned out :D:D:D:D Did not expect it to go so well tbh


IMG_20191023_214709.jpg
IMG_20191023_214732.jpg
IMG_20191023_215330.jpg
IMG_20191023_215339.jpg
IMG_20191023_215436.jpg
IMG_20191023_215443.jpg
 

dann2707

ClioSport Club Member
Had a crack at some butt welding which is significantly harder than the lap joint above purely because if the lines are straight up against each other and there is a slight gap then the welder just makes a hole in between them

|()|

But like that vagina looking thing above.

It went well however a common issue I have in things other than welding is it looks like there wasn't enough penetration as the metal is not one piece on the inside.

I'll go over it again with more amps, used my pack purging templates I made on the printer for the v band flange which fitted beautifully.

At the moment in time this is all trial and error and learning the process. Although it's not an issue at all, just need to pass over again with the welder with more boost.

One thing for sure, pipe / tube welding is f**king hard as f**king s**t as when you are welding you're having to twist your arm and wrist at the same time so that you follow the arc of the tube, doing that is pretty uncomfortable but feel like I'm getting the hang of it. I used to dip the tungsten loads but now it's pretty uncommon.

Tacked

IMG_20191025_181637.jpg


Purge cup with hipster label made for it

IMG_20191025_181641.jpg


IMG_20191025_183043.jpg
IMG_20191025_182503.jpg
IMG_20191025_182519.jpg
 

dann2707

ClioSport Club Member
@Akay came around last night and we did a bit more to the car to get it in a state almost ready to remove the engine.

Removed the cat, exhaust, manifold, adz loved removing the clips that hold the gear selector to the box too. Biggest nightmare all night!

Called it a night after a few hours and then I cracked out a new gas lens for the tig and had a play with that. It's a big one to allow me to have my tungsten stickout longer for harder to reach bits when doing the exhaust and just any other general welding.

Gives lovely colour to the welds too and it's what people use when you see the sexy welds on Instagram etc.

Used the big range of milwaukee too, man I love them so much jussssst incase you haven't heard it from me before....

IMG_20191031_191649.jpg
IMG_20191031_213430.jpg
IMG_20191031_183947.jpg
IMG_20191031_183950.jpg
IMG_20191031_213441.jpg
IMG_20191031_205551.jpg
IMG_20191031_214304.jpg
 

Waitey

ClioSport Club Member
  Rangie Sport, Westie
Please don’t use those Y joins, get someone like CSK to make you some proper collectors up.
 
  MR2 Mk3 / Giulietta
You forgot when we struck platinum! Best part of the night.

Told you those selector clips were c*nts. Still having nightmares about them!

Big thanks to Milwaukee™ for assisting.
 


Top