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http://s4.zetaboards.com/lexusaltezzaclub/topic/1148393/1/#new



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2j + 3s = Homebuilt Hybrid; My Motor Assembly pics
Topic Started: Feb 17 2009, 07:36 PM (9,462 Views)
Distrb
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Nuts
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Thanks to some sharp pricing, generous donations, and a MEGAMEET sized care package - i am pleased to be able to reveal the following:

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Thats:
1 x 3SGE Manual Longblock (80K old)
2 x 2JZGTE pistons
1 x set Big end Bearings
1 x Headbolts
10 x sparkplug
1 x main bearing shell
1 x engine gasket set

looks like tonight will be spent stripping that motor and cataloging unrequired spares (i.e. the entire bottom end bar the block!)

Project is back on!
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Distrb
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Once i had picked myself up off the garage floor after the epicness that was death by retardation, it was time to get back to making this bloody thing work.

Within a day i had the motor completely stripped down, block, head rods and pistons away getting cleaned, crack tested and measured prior to reassembly.

The rod that was in number 2 cylinder was found to be twisted by around 4mm, so into the bin that went, and thanks to a friend i managed to source a replacement rod, but i needed some way to balance it. So i made up this wee jig to hold the rod at dead set level so i can weigh each end of the rod as accurately as possible. Calibrating it with the previously balanced rods to get it even before i went and put on the new rod. Worked a treat, and can balance a rod end to within a 10th of a gram
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Thanks to the previous failure, where valves met pistons, it took all of the guesswork out of how much i needed to enlarge the valve relief's in the 2JZ pistons by. so to make doubly sure, i inserted plasticine and timed everything up.

Piston with Enlarged valve reliefs
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How not to do your timing belt on a stock motor.....
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then stired a few times over, nice and slow. bring back to TDC, remove timing belt, cam gears and head, and we have......
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After measuring to the edge of the valve indent, close to around 2.5mm clearance is achieved. and that is taking into account stretch as well. i may or may not have requested a little more than required to be taken off the piston to achieve that measurement. But after what happened last time, you cant be too careful.

So with that, the whole dummy assembly was stripped down and cleaned for the last time (I have lost count of how many dummy assemblies i've done on this thing. Certainly done more than my fair share of cambelts) and now full assembly can happen. Nobody really wants to see full assembly pics in detail, so heres the brief ones.

Shortblock Assembled
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Head on and torqued down, cams also
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Motor fully assembled and ready to go back into the car
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Guess i should pull finger and get it in the car huh?

:blink:
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GT4SUM
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------>
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yeah man. I cant wait to see it going
99 Altezza RS200 Z (3sge+t)
94 Gtfour ( st205 ) - Sold

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ShoiezDesign
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.
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Ah nice work man good to see you back in the game after what happened!

Good luck!
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Distrb
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Nuts
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cheers. Took a bit longer to build than i expected (spent too much time doing motorsport related activities :D ) so should hopefully have it fired up in the next couple of weeks.
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xnickx
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^^ You may thank me ^^
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Good stuff Andrew! Can't wait to see this all done.

Awesome setup for weighing the rods too :woot:
Contacting me for parts

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Distrb
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xnickx,Nov 4 2009
10:50 AM
Good stuff Andrew! Can't wait to see this all done.

Awesome setup for weighing the rods too :woot:

lol, dunno about awesome, is a wee bit rangi, but got the job done.
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crazyeyes
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good stuff... soon there will be no need for pushing........
MM09 "HIT HIT HIT.....AHHHH IM F@#$ HIT"- paint ball
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Distrb
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So i should really update this thread now that i have a result. i bolted the following to this motor:

Garrett Gt2871R turbocharger
530cc sard injectors
Tomei FPR with fuel return
Walbro 255lph fuel pump
2.5" exhaust
front mount intercooler and piping
16psi boost
Apex-i Power FC

and the result is......

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So there you have it folks. my crazy Frankenstein motor built on the cheap using stock parts from other motors as an alternative to forged pistons and rods really works and makes some power.

Now the only question is... how long will it last? Only time will tell that.

Cheers
Andrew
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Soiled Altezza
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...
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Thats some nice looking power there :D
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Garage: http://altezza.dualzdesigns.com/viewcar.ph...wner=17&frmpg=0
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greeneyes
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Targa Master
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Good grief! Is that 245KW... or do you love colouring in the lines by hand? :lol:

So, is that RWKW, I assume its not 'adjusted' up to flywheel KW, and so its making twice a stock Altezza!

Must be fun to drive now!
The Girl's KE70-
http://www.rollaclub.com/board/topic/42407-the-girls-ke70/
How NOT to build a rally car-
http://www.rollaclub.com/board/topic/64027...ld-a-rally-car/
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Leiden
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NZ, Whangarei
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Did they play with the VVT map at all to try and even out that flatspot in the torque at 5000?

Good effort Andrew, enjoy :P
Project Thread
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Distrb
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cheers guys. the 3 lines are related to boost level. blue is 9psi, green is 12psi and red is 16psi. Is all 100% at the rear hubs (not wheels as it is a hub dyno)

Is nice and driveable but it does want to light the rears up if you are a bit heavy on the throttle. just getting used to how fast it picks up and accelerates.

i dont know how much they played with the vvt-i map around that section as andre wasnt there when i picked it up, but i'll ask him when he makes his followup phonecall. Really it moves so quickly through that rev section that you dont notice the torque dips at all
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Leiden
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Posted Image

Thats the standard map shipped on the PowerFC supplied with the SXE10 Apexi Turbo Kit. Was just wondering if they played with the VVTi maps at all, you can see in the picture above that the intake advance tails right off at 4400 and then shoots back up at 5200.

Was just curious because your torque dip starts at around 4400 and ends at 5200. From my understanding Torque is directly related to Volumetric Efficiency, and thats what the cams are reponsible for. I doubt your map would be the same though, wasn't your PowerFC originally running a stroked 2.2 N/A?

I can always send you a copy of this map and you and your tuner can take a look at it if need be.
Project Thread
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Distrb
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Nuts
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yep the ecu contained a tune for a 2.2L stroker when i got it but that didnt matter much as i figured out how to reset it back to the basemap with the hand controller before i started it up first time. from memory the vvti maps were the same for n/a and turbo versions, so no problems there. Vvt-i maps on both cams were adjusted which yeilded good results in torque and power with the most adjustments and gains being made on the exhaust side. The dip you just dont feel in the car as it pulls so quickly and smoothly through those zones on boost. No the graph doesnt look that flash, but it definitely isnt something that holds it back, so nothing to rectify as far as im concerned
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Japsfinest
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Andrew, congrats on your achievement....

to recap the mods you did to the piston between the two builds.

2jzgte piston modified to take 3sgte connecting rod.
2jzgte piston modified to clear 3sge oil squirter.
2jzgte piston modifies to clear valves, taking into account timing adjustments by vvti.

Am I missing anything?

thanks
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Distrb
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Japsfinest,Jan 9 2011
05:57 PM
Andrew, congrats on your achievement....

to recap the mods you did to the piston between the two builds.

2jzgte piston modified to take 3sgte connecting rod.
2jzgte piston modified to clear 3sge oil squirter.
2jzgte piston modifies to clear valves, taking into account timing adjustments by vvti.

Am I missing anything?

thanks

The only modifications done to the piston are these:

2jzgte piston skirt modified to clear 3sge oil squirter.
2jzgte piston valve cutouts modified to clear 3sge valves, taking into account timing adjustments by vvti

Piston was not modified to suit the conrod. It is far easier to modify the small end of the conrod to suit the piston.
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supertezz
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3SGE+T = :D
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How is the setup going now Andrew this really is a great alternative to blowing a lot of cash on forgies looking at doing something similar down the track
3SGE+T = :D

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Distrb
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Its still going well and is really enjoyable to drive. I think i've put around 8000kms on it now. I'd really love to get hold of a bore scope and have a look down the bores to see what it is like.

Overall the tune is quite conservative and is sitting on the limits of injector duty (currently at 85% on 530cc injectors) at the moment. No plans to try and squeeze any more power out of it as i generally drive around on 12psi boost on the road, with the odd shot at 16psi to keep me feeling mortal.

Pretty sure the motor itself is capable of handling more than i am throwing at it. I've thought alot about what it'd require in terms of parts, cash and time to take it to the next level of power output (+300kw), but i cant justify going any further given the lack of disposable cash i have and how much i am enjoying it in its current state.As far as i am concerned i've achieved what i set out to in the beginning, so i'm content :)

If you are looking at doing something similar at some point feel free to give me a yell as i'm happy to help where i can
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