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1982 Starion Build


ZacMan
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I made up a mount for the injector ballast resistors. Flow tested the injectors too, and they came out at bang on 560cc/min. Spray pattern was not perfect, but its a single cam, so probably wont make much difference.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/IMAG0030.jpg

 

My turbo bits showed up. New evo 3 7cm^2 turbine housing, and a TD06 16g compressor housing. I was going to use the TC06 compressor housing I had, but having it machined out to fit the 16g wheel was more expensive than a new housing... So that made it an easy decision. Just switching to a bigger housing wont have much effect on performance or spool. Plus, its a 3" intake, so makes the intake piping easier and tidier http://oldschool.co.nz/2011/forum/public/style_emoticons/default/smile.png.

 

Oh, and it looks fricken awesome http://oldschool.co.nz/2011/forum/public/style_emoticons/default/smile.png. I have to adjust that end of my intercooler piping though, but no biggie.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/IMAG0027.jpg

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  • 4 weeks later...

Oh happy day!

 

Had a right time, right place situation yesterday that resulted in me now owning this:

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P1090061_1024x768_zps949be9e4.jpg

I've always wanted a black interior, and this was the only part I'm not confident of being able to change the colour of and get a good result. Quite stoked.

 

Got some work done on my down-pipe the last couple of days. This is only the second one I've made with a divorced wastegate pipe, they're a bit tricky, but should do the job. It'll have a flexi in it too.

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P1090062_1024x768_zps6abe96e9.jpg

 

Fits!

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P1090063_1024x768_zps7954e749.jpg

I've tried to keep it as close to the firewall as possible to hopefully leave room for a steering shaft when I one day switch to rack and pinion. One day in the Distant very far off future, like when I fit that dash... Both will be a long way off.

 

I've been looking into electric powersteering pumps from MR2's also. One of the guys at work has one fitted to his racecar and it looks like an interesting bit of kit. Apparently it should work okay with a box instead of a rack. Will have a go at fitting one, as it'll keep things nice and tidy, and allow me to put A/C back into this thing.

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A little more work on the downpipe yesterday. By happenstance the meeting point for the wastegate pipe and the main pipe was right on a join in the main pipe, this will make welding the whole thing together much easier.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P1100056_1024x768_zpsd8c768a4.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P1100058_1024x768_zps12ee322b.jpg

 

Then I turned around and saw this:

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P1100060_1024x768_zpscba7b220.jpg

 

I decided s*** was a little too out of control, so spent the rest of the day cleaning the garage :).

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http://i750.photobucket.com/albums/xx141/ProZac83/P1110056_1024x768_zps002c9c03.jpg

 

Ahhhh, that's better.

 

Ideally, I would have liked to finish my downpipe this morning, but I did the exhaust on my father in laws mini earlier on in the week, and left my welding helmet out at their house, so it will have to wait.

 

Decided I'd take a look at the turbo:

 

http://i750.photobucket.com/albums/xx141/ProZac83/P1110057_1024x768_zpsf11c18d5.jpg

 

Rebuild kit is from Kinugawa, and looks like it'll do the job, all the pieces are there anyway. I cleaned everything else up, and sorted getting it balanced next week.

 

I bead blasted the nugget a while back when I was doing some other pieces, and thought I'd put this paint to the test. I've had good results from it before, will see if it can work in this situation.

 

http://i750.photobucket.com/albums/xx141/ProZac83/P1110059_1024x768_zps2fc86b37.jpg

 

Couple of light coats, and one wet coat. Leave it to dry for a couple of hours, and then chuck it in the oven as hot as you can get it for 30 min's or so. It's still in the oven now, cooling down again. We're shooting off 4wding for the weekend, so can stay there till we get home :).

 

Had another 30 mins to kill, so I installed some new wheel bearings in some front hubs, which I previously shortened the studs on. I don't like slip on spacers, so I had some 15mm hubcentric bolt on ones made. The studs are shortened so when the spacers are installed, the end of them is flush with the end of the nut. This provides clearance for the wheels to seat properly on the spacers. Should get the front wheels sitting just right. I've got some 20mm spacers for the rear too, to take care of that end. Will shorten those studs on the car though, as rebuilding the rear end is way down the priority list at the moment.

 

http://i750.photobucket.com/albums/xx141/ProZac83/P1110060_1024x768_zps51162df5.jpg

 

Much nicer working in a somewhat tidier garage... 'Tidy house, tidy mind' really does ring true.

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  • 2 weeks later...
  • 3 weeks later...

While I'm waiting for some bits to come back from engineering places, and some overseas stuff to arrive, I though I'd have a go with an electrostatic flocker one of the guys at work has.

 

I scored these A pillar trims off FST4RD a while back, and they were pretty gross. The plastic was all flaking off and chalky, and the driver's one was yellow from cigarette smoke. I attacked them with 80grit and got all the flaky/chalky stuff off, then gave them a hit with some satty-b.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2020004_1024x768_zps502562f7.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2020006_1024x768_zpsd8913d31.jpg

 

They still had massive sanding marks in them from the 80 grit, but looked marginally better. All that vinyl type texture was long gone though.

The flocking process is a bit time sensitive. Basically, I used a sponge roller to evenly apply PVA glue to the entire surface, being very careful to get it into all the corners and tricky places. Now, you need that PVA to stay wet and not develop a skin. You hook the machine, which is basically a hopper attached to a static field generator, to the workpiece. It produces electrostatic field strength somewhere in the vacinity of 40000 volts I believe. This electrostatic field between the hopper and the workpiece causes all the flock fibres to 'declump', and fly out of the hopper, towards the workpiece at a pretty decent velocity. Where they hit the workpeice, the glue catches them and holds them tight. Due to the orientation of the field, all the fibres hit the workpiece end first, making them accumulate quite densely. The finished product is very similar to velvet or suede.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2020007_1024x768_zps796323be.jpg

 

I kind of stuffed up the first try, and didnt have the glue everywhere I needed it... But PVA is water soluble so if you're quick enough, you can wash your stuff up away, hah.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2020008_1024x768_zpscf7552d3.jpg

 

After letting the bits dry overnight, the fibres are stuck good and proper, and it seems to be pretty hard wearing. I did the gauge cluster cover too, to eliminate the glare on the screen it causes.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2060012_1024x768_zps66d2e146.jpg

 

A couple of the guys at work have done their entire dashes, and they look pretty cool, but I dont know if it would suit a starion dash, with the big flat areas they have... thoughts?

 

Also, the flocking fibres are attracted to anything vaguely damp... As It was a really hot day, and I was being a sweaty fool, it was a bloody messy job, exibit A:

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2020009_1024x768_zps67e43c7f.jpg

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  • 3 weeks later...

Mike's car had been for sale up north for way to long... After a couple of glasses of wine one night I was chatting to the other half, and she convinced me it made more sense to buy that, than have my one painted at the moment, as it'd be cheaper overall.

 

That's totally how it went down.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200007_1024x768_zpsdeb535e7.jpg

 

Will put all my MPI SOHC gear into this one to get it going again. Not sure on the fate of the black one, but twin-cam's of goodness call to me for that car...

 

Anyway, I've never had a 5-stud Starion before.... But with this one being so, it means I could try on a bunch of wheels!

 

Some Diezel D1R's that were sitting around at work. 17x10, 17p offset all round. Perfect fit on the rear, but defonately a no-go on the front. I don't really like how they look though.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200009_1024x768_zps5f4cdc93.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200011_1024x768_zps5f4cdc93.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200008_1024x768_zps49c577d3.jpg

 

A friend of mine has a quite insane 280z, and it has equally insane wheels. These have been modified to be three peice on the rear, and are now a bit over 10 inches wide.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200012_1024x768_zpse393865e.jpg

 

Needless to say, I'm completely sold, and will have to get some made! (Once the rest of the car is running).

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200014_1024x768_zps82557400.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2200015_1024x768_zpsd9ac21e0.jpg

 

Didn't have any low-profile wheel-nuts to try on the XXR527's, which was a shame, another time maybe. Would need spacers though.

 

I also did a bunch of other boring work like mounting the EVO V ECU, building the loom, getting intake and exhaust manifold flanges cut and sourcing all the materials to build some manifolds, but none of that s*** deserves pictures :).

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Got a couple of hours in today. I need a starting point for all the wiring, so the ECU is the logical place. Had to make a mount to put the EVO V ecu in the factory spot, and still have all the trim fit nicely.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2230005_1024x768_zpsc134c0d3.jpg

 

Once you see the DomoKun doing Karate, you can't un-see it.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2230002_1024x768_zps5cc9e53a.jpg

 

How the ECU fits in. It's nice a snug, but I'll add some foam padding anyway to keep the vibrations down.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2230006_1024x768_zpse6da93ac.jpg

 

In place. I put a hook on the back of it like the factory ECU cases have, so it held in there pretty well.

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2230007_1024x768_zpsc02835ac.jpg

 

Trim still fits, yay!

 

Tomorrow I'm going to look at the seat rails. Mike had them fitted in there, but had fallen victim to the trick of the driver side having different height mounting points at the front, so it was a bit OTP. Ive got a BRIDE seat rail from an S13 for inspiration... Actually, it'd be pretty easy to make the Bride rail fit, but it's not mine... Bride do rails for starions, but they cost money. Anyway, I'll mash something up hopefully.

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Went and got some steel today for the seat mounts. The red car came with some quite nice Recaros. I'm not 100% sold on them over factory seats, but they're pretty nice. The mounts that were on them were just some pieces of flat bar bent up in various ways and welded to the rails. Unfortunately the different height of the front mounting points on the drivers side of a Starion hadn't been taken into account, so the drivers seat was a bit on the piss.

 

S13's apparently have the same sort of deal with different height mounting points, and there was a set of Bride rails for one sitting at work. I borrowed the drivers side for inspiration, and got to the chopping. Everything is working out pretty square to the floor of the car, and will make mounting the rails properly and evenly nice and easy.

 

S13 Bride rails:

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2280002_1024x768_zps802dc281.jpg

 

The beginnings of what I've come up with:

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2280001_1024x768_zpsd6455612.jpg

 

Test fitting the seat and rails on top of what I've built confirms that the seat is still pretty low, a good 3-4 inches lower than a factory seat, which weren't particularly high in the first place... Will have to play around a bit more and make sure it's not going to be too low.

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  • 4 weeks later...

Making progress on the MPI inlet manifold:

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/IMAG0091_1280x766_zpsb2c9542b.jpg

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Cheers Shadow TSI, its proving to be a heap of fun :-). It's easy to keep the motivation high how that I know once I've done all the mechanicals, I don't have a massive waiting in doing the body too!

 

Today was a good day, massive thanks go out to Martin up in the North Island, another major part of the puzzle has arrived:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0097_1280x766_zps4eb7f625.jpg

 

Sweet sweet black leather front seats. They need a couple of minor repairs to the adjuster mechanisms, but nothing major, and are totally Awesome :). I've always always wanted a set, and now I've got them! Whoopee!

 

The wheels for it arrived, thought it would be interesting to show the fitment:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0093_1280x766_zpse7539f93.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0094_1280x766_zpsd975e927.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0095_1280x766_zpsa2ecd3e1.jpg

 

They're Rota Torques, in 17x9.5 and 17x9.0, both 12P offset. I know, I know, photos of wheels without tyres are just plain dumb, but I didnt have time to get these fitted:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0096_1280x766_zps5a304422.jpg

 

Nitto NT05 235/40/17 for the rear and Nitto NT555 215/45/17 for the front. Slightly smaller rolling diameter than the factory wheel and tyre setup, but once the car is a bit lower, it should look pretty cool. I would have liked the NT05's all round, but they didn't do them in that size... Plus, it's a street car, it's really not going to matter.

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Went and got some steel today for the seat mounts. The red car came with some quite nice Recaros. I'm not 100% sold on them over factory seats, but they're pretty nice. The mounts that were on them were just some pieces of flat bar bent up in various ways and welded to the rails. Unfortunately the different height of the front mounting points on the drivers side of a Starion hadn't been taken into account, so the drivers seat was a bit on the piss.

 

S13's apparently have the same sort of deal with different height mounting points, and there was a set of Bride rails for one sitting at work. I borrowed the drivers side for inspiration, and got to the chopping. Everything is working out pretty square to the floor of the car, and will make mounting the rails properly and evenly nice and easy.

 

S13 Bride rails:

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2280002_1024x768_zps802dc281.jpg

 

The beginnings of what I've come up with:

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P2280001_1024x768_zpsd6455612.jpg

 

Test fitting the seat and rails on top of what I've built confirms that the seat is still pretty low, a good 3-4 inches lower than a factory seat, which weren't particularly high in the first place... Will have to play around a bit more and make sure it's not going to be too low.

 

Been playing with different solutions to this myself. My compliments on your work ZMan!

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I found the best solutions was to ditch the aftermarket seats the car came with, and put some factory ones back in! Mitsubishi for the driving position so 'right' Its a shame to mess with it IMO. Got good coin for the recaro's too!
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I've got a mid-term on thursday, so I'm studying pretty hard for that at the moment.. But occasionally when I encounter brain-fade I pop out to the garage for an hour or so. Not much time to get anything done, but it's nice to make little bits of progress.

 

Today I continued work on the manifold. I needed to cut the holes in the plenum baseplate for the runners to pass through. As these holes are pretty big, and overlap, it was always going to be tricky with a drill or similar. A friend of mine suggested using a chassis punch. He works at a hydraulic tool supply company, and loaned me the gear. The punch made short work of the job, and gave a bloody awesome result!

 

First job was to mark out where the holes need to actually be. This was pretty easy to do once I marked out a centerline. I used the flange as a guide, a little measuring, and the hole centers were easy to fine. I drilled these points out to 10mm for the chassis punch to fit through.

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0103_1280x766_zps081de23b.jpg

 

I checked these marks against the machined runners, and it all lined up.

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0102_1280x766_zpsb7ca505d.jpg

 

This is what the chassis punch looks like:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0104_1280x766_zps752b7b63.jpg

 

The ram pulls the center support down through a cup that is marginally larger than the cutter, which is threaded onto the top of the support... Pulling the cutter into the cup, through whatever is in it's way. I first had to take my 10mm holes out to 3/4":

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0110_1280x766_zpsdea33f46.jpg

 

This was so I could fit the bigger center support in the punch, which happens to have a shaft size of 3/4". With the bigger chaft in place, I could use the correct size cutter:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0113_1280x766_zps4699ff83.jpg

 

After cutting all these holes, I was left with this:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0115_1280x766_zps5d77dc24.jpg

 

lining this up on the flange showed everything to still be pretty concentric.

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0116_1280x766_zps097b1459.jpg

 

This is about where it will sit on the runners:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0118_1280x766_zps980620c2.jpg

 

With it here, there is still enough room to get a decent plenum area in between the strut tower, yet still be able to install or remove the distributor.

 

I plan to do a bunch of study tonight, so maybe i can sneak a couple more hours in the garage tomorrow to further progress with these bits:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0119_1280x766_zps98ad2c6b.jpg

 

I also dropped my wheels and tryes off to be mated this morning, then picked them up on the way home. Please dont laugh, the car looks bloody awful at this height. When I'm back at work next week I'll order the D2's for it and sort that issue out! The wheels would look nicer in silver I reckon, but Bronze is fine for now :).

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0100_1280x766_zps70fbef68.jpg

 

There are 25mm spacers all round. I'll leave them as is till It's at ride heigh and I can see what sort of clearances there are. I bought 25mm spacers so I've got meat there to machine down to get them just right :).

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I've got a mid-term on thursday, so I'm studying pretty hard for that at the moment.. But occasionally when I encounter brain-fade I pop out to the garage for an hour or so. Not much time to get anything done, but it's nice to make little bits of progress.

 

Today I continued work on the manifold. I needed to cut the holes in the plenum baseplate for the runners to pass through. As these holes are pretty big, and overlap, it was always going to be tricky with a drill or similar. A friend of mine suggested using a chassis punch. He works at a hydraulic tool supply company, and loaned me the gear. The punch made short work of the job, and gave a bloody awesome result!

 

First job was to mark out where the holes need to actually be. This was pretty easy to do once I marked out a centerline. I used the flange as a guide, a little measuring, and the hole centers were easy to fine. I drilled these points out to 10mm for the chassis punch to fit through.

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0103_1280x766_zps081de23b.jpg

 

I checked these marks against the machined runners, and it all lined up.

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0102_1280x766_zpsb7ca505d.jpg

 

This is what the chassis punch looks like:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0104_1280x766_zps752b7b63.jpg

 

The ram pulls the center support down through a cup that is marginally larger than the cutter, which is threaded onto the top of the support... Pulling the cutter into the cup, through whatever is in it's way. I first had to take my 10mm holes out to 3/4":

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0110_1280x766_zpsdea33f46.jpg

 

This was so I could fit the bigger center support in the punch, which happens to have a shaft size of 3/4". With the bigger chaft in place, I could use the correct size cutter:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0113_1280x766_zps4699ff83.jpg

 

After cutting all these holes, I was left with this:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0115_1280x766_zps5d77dc24.jpg

 

lining this up on the flange showed everything to still be pretty concentric.

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0116_1280x766_zps097b1459.jpg

 

This is about where it will sit on the runners:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0118_1280x766_zps980620c2.jpg

 

With it here, there is still enough room to get a decent plenum area in between the strut tower, yet still be able to install or remove the distributor.

 

I plan to do a bunch of study tonight, so maybe i can sneak a couple more hours in the garage tomorrow to further progress with these bits:

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0119_1280x766_zps98ad2c6b.jpg

 

I also dropped my wheels and tryes off to be mated this morning, then picked them up on the way home. Please dont laugh, the car looks bloody awful at this height. When I'm back at work next week I'll order the D2's for it and sort that issue out! The wheels would look nicer in silver I reckon, but Bronze is fine for now :).

 

http://i750.photobucket.com/albums/xx141/ProZac83/IMAG0100_1280x766_zps70fbef68.jpg

 

There are 25mm spacers all round. I'll leave them as is till It's at ride heigh and I can see what sort of clearances there are. I bought 25mm spacers so I've got meat there to machine down to get them just right :).

 

I have a chubby. Wish I had that kind of a tool setup. :blink:

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Me too! It's very much not mine, will have to return it tomorrow. Would be very very handy for making intercooler piping passages through sheet metal though.
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Today I swapped the suspension over on the cars, was actually quite a bit of work, I'm bloody knackered now.

 

Good new though, I reckon the red car looks awesome. When I first had the wheels on it with the stock suspension, I wasn't convinced they were the right choice, but now, they look kick-tail :).

 

The wheels still wouldn't fit the front, even with the coil-overs, and needed spacing out. This meant I had to roll the guards, which didn't go so well, paint wise. Will have to take it to a body shop to get it all fixed up. It's also WAY to low, needs to be raised about half an inch, 5mm machined off the rear spacers and 10mm off the front, and I think it'll be pretty much perfect :).

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/IMAG0125_1280x766_zps685b0771.jpg

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More pics with a still, but less, s*** camera:

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P3290021_1024x768_zps0a79d353.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P3290022_1024x768_zps646c2c77.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P3290026_1024x768_zpsbd59a357.jpg

 

Shows fitment with 25mm spacers either end. Not quite touching in the rear, but too close and no room for suspension movement. Will machine spacer 5mm, roll goard and raise 1/2", should work hopefully.

 

Front guards are rolled now, but no room for suspension or steering. Will machine 10mm off spacer, raise 1/2" and go from there.

 

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P3290023_1024x768_zpsed0e557e.jpg

 

http://i750.photobucket.com/albums/xx141/ProZac83/Starion%20Project/P3290024_1024x768_zpsbc528514.jpg

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