Red Gti-r DIEGSR - Complete Rebuild

Hi All,

Some of you may have seen this build thread, but with sites closing down i thought i better move it to a few more locations, also i will be adding to it shortly as i have done a lot more work on this car over the last year.

Since about september 2009 i started doing my partners gti-r up which had been sitting infront of the house for three years.

First things first the engine was toast. Some clown shoe's had put valve grind into it with an oil change.. You can imagine the results.

So I was on the hunt for a new engine. After 3-4 months of looking i found one i thought was the business. 180psi of compression on all four cyliners. MINT!!

So out came the old engine.

And in with the new one.

Once we put the new engine in we poped the rocker cover off.

And to my shock the intake cam was completly rooted. Looks as though one of the top oil sqirters had blocked and starved the head of oil..

Great!

So out with the cams, rocker arms and shims..

I re-drilled the oil sqirters to a slightly larger diamater and blew all the rubbish out of them with a air compressor.

So i found some second hand cams in the garage with some rockers and put them back in. After some very painful Re-shimming the head was good to be started again.

As you can imagine after sitting in the weather for three years untouched just about everything was stuffed on this car.. So alot of stuff was just replaced. c.v joints and boots, shocks, a few bushes. was a nightmare.

To top things off once we tried to start it it would not go..

After some mucking around i decided to go see Barry at MSM motorsport in Penrose Auckland if theres something i cannot work out on a nissan I know Barry is the man to see. Top bloke recommend him to everyone.

After a swift wack around the head from him we descovered that the cam timing was out by 2 teeth..

Doh!

So after re-doing that.. (you know what that means getting that dam cam chain tensioner out and back in..) the car sprang to life..

Followed by massive clouds of white smoke.. expected though the turbo had been sitting for 3 years. On inspection the oil seals had gone. So i decided to give DSR turbos ago..

Turned out to be a bad idea .

But everything was going and in the midst of it i had installed
550cc injectors
Q45 MAF
my old PLMS daughter board into the ECU with 4 way map switcher
greddy profect B boost controller
Apexi air filter
Jun Light wieght flywheel
5 puk carbon kevlar clutch and uprated 2300ibs pressure plate
Front mount with custom piping
3inch exuast with 3inch custom downpipe
DSR 380 turbo
Polished top plenuim
HKS limited edition B.O.V
Plus a few more things iv probably forgotten about.

So it was off for the tune.

We later found that the DSR turbo had a manufactures fault and would not boost past 10psi..

But i was entered in the 4 & Rotorary Nationals 2010 so we tuned it the best we could and went racing... well driving 400m in a streight line.


The car with the old engine about to be removed above.


Engine all removed above.


Jun Light Weight Flywheel


New Clutch


Head Stripped and Cams out after damage found on new engine.


One of the damaged lobes from the intake cam


New cam in place


Car all back together and going!


Running at the 2010 4 and rotarys

So ended up doing 13.7 as the best time in the car with the rubbish turbo.

So i went and bought a Garrett Gt25/40.

On some real good inspection on the hoist i found that the shell was developing some good rust in the wheel arches. Along with the side of the car and also a old weld repair on the rear quater was starting to come through..

I though stuff this and purchased a new shell.

The Shell used to belong to a mate who poored over 60k into the car i think. I was lucky enough to get a ride in it before he sold it.

The car was stolen from the new owner and stripped.

But the shell was recovered.

I picked it up in the condition below






So the ground up rebuild begain. Two shells one set of running gear and a bucket of money...

So the swap over begins.

Ok the strip down.

8.50am i arrived at my MSM Automotive Limited with a running driving road legal Gti-r

By 5.30pm we had fully stripped it down to the bare shell.











Special note: DSR turbo thank F&*k this came off the car! worst turbo i have ever had!




[/img]https://2img.net/h/i28.photobucket.com/albums/c241/the_magic_touch/internet14.jpg[/img]

The New Shell


So the rebuild of every component in the car starts..

First up was the gearbox and head.


Turns out i need 1st, 2nd, 3rd, 4th, and 5th gear syncro's and 2nd gear hub.
Ouch!



New Bearings and syncros arrive. Also second gear hub. Nissan had just raised there Gti-r gearbox bits in price as well.

Sent the rear subframe off to be sandblasted and reconditioned. Is now fully rust coated appoxied and painted. Looks great! Also added some full aluminum rear subframe mounts!



So the head was popped off and we started to disassemble it.




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So the head was stripped so i started to assemble some bits and peices for it.
272 degree Franklin Cams

Adjustable cam gears

New Valve steam seals

Manley uprated valve springs

Cometic head gasket

Bought some ARP head studs and fitted them into the block



Ok so things were happening

Rebuilt start motor
Rebuilt steering rack
Rebuilt power steering pump
New Water pump
Oil pump checked and cleaned
Head removed
Skimmed
Valves cleaned and lapped into there seats
New uprated Valve springs fitted
New APR head studs fitted
New cams fitted
New tensioner fine tooth fitted
Whole under side completed bar the calipers


New rear Teflon braided lines for the rear fuel tank all cut and ready to go.
This stuff is about twice the price of braided line but for a reason its sooo much better.

Cleaned, Primered and painted the whole under side of the car myself.. What a mission

Steering Rack after rebuild

New ball joints in front arms

One of the many to come brackets that i polished

Lapping in the valves...c**t of a job.


Head having its final touqe down to the block with Steel head gasket


Top half of the plenuim coated in thermacoat heat protection

Water lines coated in the same heat protection coating

Rear subframe bolted into place

Aluminum mounts in the rear subframe


Bolts and bits and peices coming back from being Re-nickle coated.

Brand new bolts for the more generic stuff

Steering rack back in place with nolathane mounts


New Tensioner in, Adjustable cam gears in, 272 brand new cam shafts in, brand new uprated valve springs in, New steel head gasket in.


Plenuim coming back together with the throatle bodys that i hand polished.. 70 hours later


Reconditioned power steer pump back on


Polished diff rear housing and painted diff casing back together and ready to go in. Once again i hand polished the rear diff casing.. 30 hours later..


Jam racing coilovers having a touch up



Rear diff in the subframe

Painted front control arms and hubs

Rear brake disks DBA4000 series.

Custom made muffler for the rear of the gtir will flow really well but make the car legel for the roads.

Plenuim on the engine bolted down


Water pipes fitted and heat wrapped to try and avoid heat soak.


Painted vacum canaster and all new vacum line at the back, Plus oil filter relocation kit fitted.

And the most fun part working out and reshimming the F^%king head

Jun Flywheel installed

Brand new exceddy clutch kit installed


Gearbox going onto the engine




Polished distrubutor and coil bracket on

Polished alternator done also nickle coated the pulley as well and bolt.


Braided line on, loom on

Engine in ;D




New Stainless Alen key bolts and washers to replace all the gaurd bolts


The person who stole the car had fun cutting every single wire in the car...Good on you mate!

Setrab oil cooler..


Front underside so far

Back underside

New longer wheel studs

Lengthened the injector loom and put sard plugs on

Underside completly finished


Cars first night of starting!


Hood lining done as well

Ok so in between here and being finished there are not alot of pictures as it was a very mad rush to have the car ready for the 2011 4 and rotarys show and drags.

We made it though







.
Unfortunilty the drags the next day didnt go so well. Blowing the ringlands on the first run causing the car to be parked up for the rest of the day... So engine out next week for a bottom end rebuild with some forged pistons.



So the engine let go on 26psi on its first run down the drag strip. 7 months of hard work by me and my mates. Also MSM Automotive. The only thing we did not touch in the build was the bottom end as i have run Gti-rs with 500hp on stock bottom ends before. This one did not last so well though.

So the block has been removed and has been sent to Reg Cook. It will return good for 700hp.

The Damage



The ringlands just didnt like the boost... Stay tuned i will update this as the engine comes back together!
I have also fitted front and rear nismo mechanical lsds as well

Well i imported a few bits from the UK at the start of the year:

AP 6 pot front calipers and 330MM twin hat rotors with machined adapter plates for the calipers
Full Carbon Fibre bonnet
Full Carbon Fibre wing
Carbon Wing mirrors
Carbon front grill
A custom gear stabilizer bracket to make selection more firm
Adjustable rose jointed sway bar links front

That all went well got them into the country.

Had the bottom end forged by reg cook. CP 87mm forged pistons, Eagle Rods with the 19mm bearings suited to gti-rs, all new nissan bearings, and all the other bits and bobs, oil pump done, oil galleries machined to flow more pressure, new water pump, new cam chain, crank was crack tested, engine blue printed and everything balanced.

Then i was lucky enough to stumble on a fully set up Jun cylinder head. So that is now fitted to the car with Jun everything. Stainless valves and retianers, Jun valve springs, Jun 268 cams, Jun adjustable cam gears. Should be good.

Imported the new Tomei head gasket from japan.

Imported three new gauges from USA Autometer.

Got all my interior carbon coated including rocker cover as well.

Now just got to put it all back together.














Then i had the issue of i didnt want this to happen:


So i did this:







Also clutch pedal mod to stop the clutch pedal coming away from the fire wall.





Enjoy

Fitted that up.

Fitted a set of these



Got hold of one of these rear braces with pointless roll bar.



Then it came time to fit the brakes.



330mm rotors and 6 pot AP calipers. Needless to say they are large.



In fact they are larger than my 15" wheels currently on the car..




All the bolts had started to rust on the twin hats so decided to start replacing them.



Fitted them to the car




My partner bought down bacon and egg pie with MSM on the top. Nice

Well while it was on a hoist. Changed the rear diff over to a Nismo Mechanical item.



Only picture i got whilst this was happening. Diff oil is messy stuff.

So with the brakes on.. i then had the issue of my old wheels did not fit.. ok time to start looking for some new ones.

I hate wheel shopping!!

Started with some Enkei racing wheels. 4x100 38P 17x7.5




They did not fit. Dam i liked the look of them.

So SSR Light weight wheels where up next. 4x100 38P 17x7.5




Needless to say they did not fit.

Well ok,

How about some Rays 4x100 40p 17x7



They went on well. Only 5mm spacers needed to make them fit. Sat inside the guards and did not foul on the struts. Only trouble is i didn't like the look of them.

So..OZ Racing wheels, these where my second choice to buy. They were heavy but made well compared to some of the other wheels. 4x100 18x7 40p




Fitted and looked good, the only thing that bothered me was the weight. To heavy.

So Tried some Advanti light weight racing wheels. I liked them until i flipped them over and saw the nasty casting marks. No thanks looks weak.



These would have been my first choice if they would have fitted. So nice. 5Zigen racing wheels 18x7.5 4x100 38p.





No way where these going to fit though. without wide kitting the car and running 20mm spacers.

I then was given these to try.. was not that keen on them. But they were so light. Forged, expensive but made for racing. Enkei wheels, 17x7 40p 4x100.





When put on they bolted up perfectly. We can almost get away with running no spacers at all. 5mm spacers will be run to start with though.

So they were bought, Toyo T1r tires fitted.

And here is what is currently on the front to move the car around the workshop. 15mm spacers required.

Ok so wheels and brakes are done. Fluids in brakes bleed. Can't wait. Just a few small things to finish off and we are away!!!.









This is where i am currently at in the build as of the 12/4/2012. Hope you all like my build so far.

Another night another step in the right direction.

Shims checked, valve clearance checked, dash installed gauges wired up. Gearbox brace fitted fully. The final touches tomorrow will be engine oil, radiator fluid, battery. Start time!!

First start up video

https://www.youtube.com/watch?v=fO6hW4Lo0sA&feature=youtu.be

How the carbon affect was done:

https://www.youtube.com/watch?v=iP7BKHU4WUc


So

got the car going, warranted, registered its all ready to be driven. So took it home to put in the garage.

[]

Has not been home in 2 years. Nice to see another gti-r sitting in the garage again.

Photo of the head with rocker cover off.



One of the rear nissan brace and over head loop..



Quick shot of the inside



Just before the drive home



Back home with the bumper back on.





In the garage

A video a mate made over the 2011 show and drag weekend when it blew up.

https://www.youtube.com/watch?v=LCKxCzJ0q_M

And my youtube channel if anyone wants to subscribe.

https://www.youtube.com/user/gtircrazy/videos

Wow!
What an impressive build.
I knew you had done a lot to the car but didn't realise it was this intense!
Stunning car and build to say the least.

Hey dude I've seen this somewhere else great build good to have you on board