Manuel Kasko 33 Build/journey

[Manuel Kasko]

Finally decided to start a build thread.

It's gotten to the stage that the car has come a fair way since I purchased it.

Right now I'm moving onto the next stage of mods and decided I will keep track of it all on here.

I also am notorious for asking thousands of questions, so while this will be to track the progress of the car feel free to help where ever you notice I need it.

Lets start off 2 years ago when I owned my first car a Mazda 323.

I was driving up the mountain on my way home from the coast, my fuel was on nearly empty and it was 50km to the closest petrol station. To save on petrol I decided to chuck it in neutral and coast down the hills where I could.

All of a sudden the car just turns off and rolls to a stop. I though fark this is odd so I started it back up and then noticed HOLY SHIAT my temp gauge was at ultra high!

That was the end of the 323, the radiator busted and took the engine with it. I was too busy looking at the fuel gauge that I didn't even notice the temp spike as I went up the mountain.

I went in search for a skyline and found one priced at 10k

After some swift negotiation I left with the car for $7500 and the guy got to keep his fully hectic sound system.

The addiction and build begins!

The car came with a few little extras as do most of the skylines these days.

- 3inch exhaust

- Boost T (set to 13psi)

- Boost gauge zip tied on the steering wheel.

- 19inch chromies for extra grip and awesomeness

- Splitfire coils

My biggest mistake I have ever made was follow the advice of my ricer mate.

We decided to wrap the dash.

What is about to be seen can not be unseen haha.

It didn't take long before I quickly sort out a new dash and installed it.

I swore to myself to never do that to my skyline again.

The search for more power lead me to create thousands of threads (as you all might know)

Also sending numerous messages to DVS Jez and Stao from Hypergear.

Finally it was decided that I would go the route of a Hypergear SS1PU with the mods to suit.

I started collecting parts.

[zebra]

Aha bout time this popped up.

[Got a Pulsar]

Ahhh yes. The Hectic Chromies and the Playdoh dash... How could I forget?

[Trozzle]

Good stuff fag!

[Sinista32]

very interesting

[Manuel Kasko]

So the parts started getting collected
It started off requesting a boost controller as a Christmas present

My girlfriend was so kind as to get me the following.

This got installed straight away.

I had a few guys from down the coast try and help me set it up.

Instructions were very confusing and the guys settled with it spiking to 18psi and settle at 12 haha

They thought that was fine and left.

So I spent the next hour or so driving around and fine tuning it.

Finally got it to hold a steady 12psi and ramp up fairly quickly.

The next step was to purchase the turbo and supporting mods.

-Hypergear SS1PU

-555cc injectors (sold to me as 800cc I do believe)

-Nistune and ECU

-Z32 AFM

-3inch Intake pipe made by Scotty here on the forums.

Here are a few pictures of the parts when they arrived.

Also during this time I decided to have another play around and test the boundaries

I ran the following lights for about 2 days before posting some pics on here and getting told I'll be screwed if I get pulled over

Its now about time for a tune!

As mentioned above I pestered Jez for many many hours before finally deciding on a date for the tune.

It was booked in and I had to get everything installed.

Times ticking..

[Manuel Kasko]

The week before the tune was probably the most stressful week of my life!

I had to get everything sorted and drivable to get to Jez up on the central coast by Sunday.

The wiring for the AFM was done by my brother.

We ended up wiring up a plug into the loom so that I could quickly swap between the Z32 and my stock one.

This meant I could drive up to Jez and simply unplug the stock airflow meter and plug my new Z32 in.

We then started installing the turbo and everything fitted perfectly except for the stock water line.

After speaking to Stao he advised me that I could either bend it very carefully or replace it with a braided line.

The line on the manifold side gave me the most hassle and no matter what I did I just couldn't get the banjo to line up.

I rushed around from place to place trying to find a solution and finally thought it's either no or never.

I grabbed out a heat gun and heated up the copper pipe as much as I could.

Grabbed it with both hands and bent it into place.

The bolt couldn't be done all the way up and gave me hell for months to follow.

Above picture shows the struggle to get it onto the thread.

But it was finally done.

Here are a few pictures of the turbo in the car and also comparing it to the stock one that was on the car.

After the turbo was installed I started working on the intake.

This caused a fair bit of trouble as well because the BOV return and the other pipe (blowbye?)

They both were very close to the manifold and so I sourced some heat resistant hoses.

I also had to mod the stock BOV return pipes by cutting them up to fit the pipes.

The filter I picked up for a very very good price online.

Below are some pictures of the fitment.

Everything was finally done.

So I headed up to Sydney for the weekend and went straight to Jez's place Sunday morning (Thanks heaps mate I really appreciate it)

[Manuel Kasko]

So bright any early at DVS Jez's place and we got started on the car.

Jez got straight to work and fitted up the injectors for me.

He ended up dropping one of the seals down the side of the engine and spent a good 30min searching for it.

Just when he was about to steal one of his drift pig the seal shows up below the car haha.

While Jez was doing that I got to work on pulled out the spark plugs and replacing them.

At the same time we also installed a walbro 255 and connected that direct feed as well.

After a few hours of fiddling around with wiring and things Jez had finished the install of the ECU as well.

So it was time to fire her up and put her on the dyno.

This is where the day really started to turn to shit!

After spending a good hour trying to work out what was happening with the injectors.

We did some research and worked out I had actually been sold HKS 555 injectors (These were sold to me on the term they were 800cc)

The seller ignored my messages and it was too late to do anything about it.

We kept moving forward and after a few runs Jez noticed that there was something different going on.

I had told him that I would like a low boost and high boost setting.

But after the first run we found the car just kept building boost.

After a call to hypergear we figured out that the SS1PU was sold to me with a 20psi actuator.

No low boost setting for me haha.

A few runs in and we blow an intercooler pipe.

The 90deg was cracked all the way up the side.

Jez got to work on finding some scrap metal and welding it all up to make something that would work.

It was by no means pretty haha but it worked! that's all that mattered.

By this time it was late in the afternoon and we still had a few hours ahead of us.

I can't thank Jez and his girlfriend enough for their hospitality.

What other tuner do you know that stays up until 9pm on a Sunday night tuning your car AND buys you pizza!

What a farking legend!

But at least we had a night light

[Mohsen]

Kasko <3s jez

[Frosty]

My biggest mistake I have ever made was follow the advice of my ricer mate.

We decided to wrap the dash.

What is about to be seen can not be unseen haha.

[Manuel Kasko]

Hahaha bitches love the shit

[Manuel Kasko]

Got plenty more updates to come.

[Frosty]

Hahaha bitches love the shit

yeah beiber fans maybe! frienship over buddy!!

[Manuel Kasko]

You can't unfriendly me!

Ohh wooaah Ohh wooaah Ohh wooaah

You know you love me, I know you care

Those are bieber lyrics in case you didn't know

[Got a Pulsar]

I didn't know, but now I do...

What has been read, cannot be unread.

Cheers for that.

[Frosty]

You can't unfriendly me!

Ohh wooaah Ohh wooaah Ohh wooaah

You know you love me, I know you care

Those are bieber lyrics in case you didn't know

i didnt know but now i do! WHY THE FARK ARE U POSTING BIEBER LYRICS ON SAU!

you wait till i see you! phone book shall be used!

[Manuel Kasko]

So the tune was finished at about 9pm and we decided to take it for a spin.

The car felt like something out of this world! I couldn't believe how much power it had.

It was breaking traction in second as it came onto boost and I was over the moon!

Below are the dyno readouts.

It was finally time to head back to Canberra for work in the morning.

On the drive home I finally got it on the highway and decided to open her up in 4th gear.

The car came onto boost and then just hit the rev limiter, I thought fark that's weird so I put my foot down again and again it just revved out.

After a quick call to Jez he explained that it sounds like the clutch may be slipping.

I tested this theory by putting it into 5th and punching it and the clutch slipped again.

I had just spent all my cash on parts and the tune so it wasn't for a few months that I could afford a new clutch.

This ended up costing me a lot more than it was worth.

After a few months passed and another 500 threads created I had finally decided on a clutch made by KB clutches in Sydney.

I went with a heavy duty organic, the clutch was a steal and only cost me $410 delivered (It's still in the car to this date)

I ended up talking to a mechanic from Toyota down here who said he would install it for $500 cash off the books.

All of the Canberra workshops wanted $1000 + parts.

The clutch was installed and the old one handed back to me.

MAN WAS IT LOOKING WORSE FOR WEAR!

The gearbox ended up coming out 2 other times over the course of the next year.

This was all because the first guy farked it up and the second person never checked the spigot bush.

I will give a little breakdown of what happened.

-Car got returned to me with a loud grinding noise and the Toyota bloke told me "the bearings need to wear in"

-After speaking with SAU everyone here told me that there was no such wear in process.

-Booked in at another mechanic and supplied them with a new thurst bearing and spigot bush.

-Picked the car up and they told me it was the thrust bearing and they had replaced it but didn't check the spigot bush.

-The noise returned after about 2 weeks and the workshop had shut down.

-Finally saved up some money and got another guy to look at it and he found the spigot was cracked in half an grinding on the input shaft, also the pressure plate was bent and grinding.

Finally that ordeal was over and the clutch has no noise.

Now 2012 SAU Nats is fast approaching and I can't wait to get the car out on the track!

[Manuel Kasko]

It was time to get the car prepared for SAU Nats!

It was also time to get rid of those shocking 19 inch chrome rims and get some good stance happening.

My first purchase was some second hand HSD coilovers (Never will I purchase something like that second hand again)

The coilovers had a horrible clunking noise which I believed was the bushes so I replaced them as well.

After showing the noise to a few people they all came to the same conclusion that the shock was farked.

It was either the coilovers couldn't be rebuilt or I couldn't be bothered but I ended up getting rid of these because it wasn't worth it.

So I started shopping around and picked up a nice set of BC BR's from JustJap for me and my next door neighbor at the same time.

The delivery was quick and the service was great!

My sisters boyfriend Shane (Wilderboy) ended up installing these for me.

Most of the work done on the car has been with 80% Shane and 20% me (I hold the light and get in the way)

At the same time Shane installed them in my next door neighbors R34 GTT

Very clean car and I was super jealous when he purchased it!

[Manuel Kasko]

Coilovers went in and the car sat there for a few days.

While I waited for RIMMMSS!! wooohoo

After hanging around the offset thread, I had finally decided on some rims.

I went with Varrstoen 2.2.1's

18x9.5 +22

Ordered them and a few days later they arrived.

I quickly got to sorting out the tires and decided on some 235/40/18's

What do you think of the results?

[zebra]

Very naice