Jaffaz32's Boosted Stroker Build

Joined
28 November 2009
Messages
997
I will update this post later with pics.

Previously i owned a 300zx for about 6 years, this was my first attempt at building a fast car and took a naive approach of power power power. The car had the power but the setup was awful. The car was savage but didn't put it down and was unpredictable in terms of the delivery.

I learnt along the way the right way of building a fast car.

I started by raising the boost on the stock motor which was getting towards the end of it's life, decided to do a mild forged build that netted 520bhp (Flywheel) and lasted about a month. Basically Scholar Engines who apparently worked with Lotus and the Elise when it came out machined my block and heads and knife edged the crank, they slipped while knife edging and scuffed a main bearing journal, the machine shop assured me this was only cosmetic damage at the time being naive i took their word for it, but... i then couldn't everyone refused to build my engine with that crank, in the end the machine shop built my motor, after a month the motor seized, it blew most the oil out the exhausts. Guessing it was down to the crank! The garage pretty much screwed me over.

Anyway after that i spec'd the motor for 900bhp, i ordered all the parts. I sent the car to Thor Racing in the UK who stripped the car to almost bare shell, they had it well over a year getting on for two over that time they hardly done anything except strip the entire car and the engine itself. Time came where i decided enough was enough, this is never going to get done. So we went up there, after being locked in a office and threatened by the garage staff not to speak of this i returned home with a shell and boxes upon boxes of random parts new and used. Realistically no garage was going to take on this job without big expense. This garage had been charging me over the duration they had the car and not making any real progress, they also stole some of my parts again i got stitched over. The car ended up being weighed in for scrap metal and the parts sold on.

Before scrapping the 300 I started talks with a Rx7 specialist who built my brothers Rx7 about having a quad rotor (26B) built and dropped in, the idea was to sell all my parts and go down this route. Until i really considered what i could buy for the money and admitted that car was just a bad omen. At the time Ferrari 355's, TVR's, Aston's etc were reasonably priced which i considered but i knew it would be a bad idea with my urge for more power, it had to be Japanese. I wanted to go the next step from the 300zx, it came down to 2 options Nsx or R34 GTR.

I bought my Nsx roughly 5 years ago a pretty much stock low mileage Charlotte Green C30A 5 speed Na1.

The car was owned by the family of Walkers crisps in the UK for most it's life and has a comprehensive service history, trailer receipts for services etc. you name it.

The car was spotless, I loved it but wanted something a little different in both power and looks.

So i started doing basic mods, LSD's, body work etc. I went down the NA route initially ticking most options, but was very limited to what i could squeeze out the stock motor. Over the years it went from looking stock to subtly modified to the race car look. I had done allot of mods like STMPO Messiah exhaust system, Downforce intake etc.

I closely followed the forums, anytime anyone had a scare for example the crank pulley failing, water tanks splitting, oil pump gears cracking i straight away ordered the aftermarket upgraded parts. The car was mechanical sound. I covered most basis except the brakes at the time

This is when i started considering turbo kits, i really had my heart set on a single, as previously owning a twin i liked the sound single's produced and wanted to do something different. I looked at all the turbo kits on the market and went with Cody's and pick a few upgrades and custom options, GTX turbo, full ceramic coating of manifolds, turbo and exhaust system. Cody build me a custom exhaust, that had a Cat bolt in option and came straight out the back in the middle as a twin pipe.

Before purchasing Cody asked me to do a compression test, which i did. All cylinders were pretty close to each other with the exception of cylinder 6 which was just within tolerance, so i knew at some point i would need to install new pistons which i decided to purchase at the time along with head gaskets for a mild build. I never got round to installing these due to expense and not being sure if that was to be the spec i wanted to run, so still sitting in their boxes.

The install of the turbo kit was kinda a disaster but rewarding in the end, i saw that Angus kit was DIY and asked Cody could his kit be installed by a normal garage or needed to be a more specialized garage. I couldn't see why not so i arranged with a small one man garage who was a Honda enthusiast to install my turbo kit with my help, the day i got there to start the install he came hopping out the workshop and said chris i don't want to scare you but i've damaged my leg and will assist you with the install. I ended up doing most the install myself, i had done my homework knowing how most of it went together. So off i went, he didn't really help at all. I managed to get it all installed and running on a base map supplied from Cody on the FIC. The car ran fine. He then had the cheek and turned round charging me about half again the initial agreed quote for the install. He said i ran over to which i replied, no shit of course i did. I'm no mechanic, you didn't do the work as agreed with my help, i did it with very little help. that got a little messy. Again i got stitched over by another UK garage.

Anyway, i got the car tuned. It seemed to drive great on the way home and for the next couple of days then after a short while the car kept throwing me out of boost well seemed the car would just kill power mid pull and come back. Replaced loads of parts, Coils, igniters you name it. Went back to Cody who helped me with simply diagnostics. Cody assured me that a guaranteed route to resolve the issue would be going with the AEM Infinity. I was hesitant because it was sold as a kit, how easy would it be to install? who would tune it? Cody said it was pretty easy to install but i still wasn't sure and didn't want to take it to a garage who would charge allot of money per hour, having to spend days on installing it. So i decided the best option was to fly Cody out to install the Ecu and tune it, which is what we did. Install was actually very easy, Cody had the car running on the first day, over the duration we got the car road tuned and then dyno tuned. It drove perfectly the issues had gone that i was experiencing with the FIC. While Cody was here he said "Chris, your oil pressure is a little low." if it wasn't for the Infinity I would of had no idea as the gauge on the dash looked fine, so the Infinity basically kinda saved me, well made me aware of a potential serious issue. When tuning the car we had to slightly lower the oil pressure safety parameters to other cars to stop the infinity going in to safety mode until i resolved the issue. At this time the oil pressure could had been just the oil i was running, maybe the external oil cooler because the lines were crazy long or maybe even a faulty sensor. Cody had set flights to return home, the car done over a 200 mile round trip dropping Cody off at the airport with zero issues, we sat in about an 2 hour traffic jam on a hot day, no issue.

I then changed the oil, for a while it all seemed ok.

Then over the next few weeks/months the car started playing up. Cody talked me through looking in the logs the power cut was the Infinity going in to limp mode due to the oil pressure once again. From there i changed the oil again but removing my billet purepower reusable filter to a normal type, eliminated and tested all oil related things i could externally, bypassing external oil coolers, new sensors. I tested the oil pressure per manual with a mechanical gauge. The issue appeared to be internal.

Now the Dilemma i faced.

UK specialist garages charge crazy money. I didn't want to pay to have the engine removed and stripped just to be inspected as i would had to wait months for any parts or what if it was something major like a crank, full motor build etc. After speaking with Cody and going through different scenarios i decided to go on the basis of worst case. It sounds a little crazy but... it's so hard to get parts here and with the unknown of what was wrong or involved, i opted for a full build because i would have a car that is mechanically sound and trouble free with the peace of mind and confidence to drive. I thought to myself i've been here before!! my 300zx built motor blew up after a month. So i decided to over spec the motor for a element of safety. I can only afford to do this once so do it right. There was a possibility the bearing had gone due to the symptoms and going on worst case i decided the crank had to be replaced to be on the safe side. this meant stroker kits, i spec'd the engine for around 800-1000bhp i wanted to tick every box and dot every I.

I contacted several garages and specialists and decided to take my car to Plans Performance an Nsx specialist in the UK.

As we speak the car is currently in bits and with Plans, they were just as excited as myself when dropping the car off to be working on this project. The motor is apart and with the machine shop as of typing. They found that one of the bearings had gone. They have sent a comprehensive email with a to do list of other things they have found that needs addressing which is good as again I know in the back of my mind that the car will come home completely mechanically sound. So far so good with Plans but a little anxious based on my past experience with garages, time will tell.

I will post a complete spec list later with more details and info but this is a start at least.

I am member of a supercar club and i have ruined several members :tongue: - Lambo's, Ferrari's, Aston's etc. This was when boosted on a stock block running as much power as i safely dared, so i can't wait to see how it will stand with the extra power and the stroker. I have no idea what kind of cars it will be able to sit with. I guess i have that to fine out.

So as you can see i have had my share of bad luck in terms of cars, i'm a decent guy and garages take advantages of this and stitch me up in the past. I'm a little nervous but very excited.

- - - Updated - - -

When i spec'd the motor i wanted to replace everything oem while building.

I ordered the oem motor rebuild kits (these do not contain everything)

I then went online and printed off the exploded diagrams for the motor, oil systems, wiring, throttle body etc. etc.

I then cross referenced what parts i had and ordered every single gasket, seal, grommet and including all brand new sensors for everything... Some sensors were expensive like the knock and crank angle but as mentioned above i could only do this the once and needed it to be trouble free motoring.

I wanted to spend a little extra now to ensure i had a brand new motor for complete reliability and trouble free motoring.
 
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Dude, that is a shitty story. Shitty by means of you getting thrown over the coals so much. If you want big power just buy a R35 gtr... The Nsx ain't built for huge power gains. Be that as it may, the turbo kits offered here on Prime are great power adders. But they are relatively new if you ask me and usually a backyard special, " no pun intended". Throwing down 600+hp means nothing if your motor blows up.
 
Current Spec:

Body Work:

Carbon Type R bonnet (color coded)
Custom Front bumper
Led front side lights
Carbon front splitter
Carbon Canards
Downforce Carbon Intake vents
BYS clear indicators
APR GTC Carbon wing
JDM rear upper bumper
Seibon Carbon lower rear bumper partly colour coded.
Custom rear diffuser
LED tail lights


Brakes, Wheels/Tires:

Advans 17/18 in Satin black
Dunlop Z2's
EBC rotors and yellow stuff pads all round (on the upgrade list)


Drivetrain:

1.5 way LSD with ring and pinion
DriveShaft shop rear axles
SOS Carbon clutch

Suspension:

BC coilovers with Swift springs
Non compliance rear beam
Urethane steer rack bush
Non compliance front clamp set
Adjustable drop links front/back
Adjustable rear toe links
Carbon6 front ball joints top and bottom
Dali front/rear strut bars


Interior:

Bride Gias Carbon seats
Takata harnesses
Route Ks harness bar
Carbon centre console
Nsx navigation panel
triple gauge pod


Electronics:

LoveFab AEM Infinity 10 Engine management
AEM AQ1 datalogger with GPS
Various gauges
Gauge Art on Honda Nav screen


Cooling:

Koyo Rad
New oem coolant hoses
Aftermarket coolant tank


Turbo kit:

LoveFab with GTX upgrade, custom exhaust and ceramic coating.


New Motor currently being built by plans.


Block:

Brian Crower 3.4L Stroker kit. - Brian Crower crank, Brian Crower Rods
JE pistons
Darton Sleeves
ARP head bolts
ARP block bolts
Cometic gaskets
Science of speed oem oil pump with billet gear
New water pump
full set of oem sensors
full set of oem gaskets/seals
baffled sump
Power Enterprise timing belt
Aftermarket stiffer engine mounts
ID 725cc injectors (to be upgraded next year)
Ati Crank pulley
SOS EGR kit
SOS oil sensor upgrade kit


Heads:

Full polish n port
Brian Crower springs
Brian Crower retainers/seats
Supertech valve guides
Supertech stem seals
Ferrea oversized intake valves
Ferrea oversized exhaust valves
Comptech cam gears
SOS LMA kit
Full seat of new gaskets/seals


We are slightly changing the plumping of the oil feeds within the turbo system and upgrading to Russell braided lines and fittings.
Also tapping the pan for a temp sensor
Left it open with Plans regarding an oil cooler, i had supplied the parts from the SOS kit i removed.
Cleaning up the engine bay by removing anything no longer in use as suggested by Plans, less to put back on :redface:


First off Plans wanted to see the car running before starting work which is fully understandable, I was waiting for the AEM to return from USA after being upgraded, sent it straight to Plans and they started working on the car.

End of first week I received a detailed email with some advisories which was listed in order of priorities, this was outside of the engine build that covered a worn ball joints, corroded rose joints etc. Was good to see as this was using initiative to give the car a quick go over and flag anything else that may need attention.

- - - Updated - - -

Man...you have been dealt a shitty card.
I hope your luck his turned finally.

Best of luck for your journey to BIG power.

SS

Dude, that is a shitty story. Shitty by means of you getting thrown over the coals so much. If you want big power just buy a R35 gtr... The Nsx ain't built for huge power gains. Be that as it may, the turbo kits offered here on Prime are great power adders. But they are relatively new if you ask me and usually a backyard special, " no pun intended". Throwing down 600+hp means nothing if your motor blows up.


Thanks guys. I need a little luck my way this time round.


I like the R35, they look great but when they go passed, do they turn heads? not really, there is so many about here. I think every car has a breaking point, when you get to a certain point you start pushing your luck. I've done my research and know my limiting factors and not willing to push it. If a motor is built right and to the correct spec it should happily take the power, I over spec'd the engine and will never go anywhere near it's capabilities for two reasons one i did it that way for safety and reliability and two there are other limiting factors. For how much things cost it made sense to do it once rather than doing it again down the line.
 
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About time you do a build thread! I know it has been a rough road, but your luck will be changing for the better it sounds. Your mod list is impressive!! Can't wait to see the final results.
 
I wish you the very best for the project!
Here in France, the "specialists" are no better than in the UK I believe.
One of my friends had his turbo kit installed by a "reputable" shop that resulted in a cracked sleeve as they tested the engine at 500 rwhp on standard internals...
For my own LoveFab turbo kit install, I went to a Honda official dealer who did the mechanical part while I did the tuning through emails with Cody.
Still working fine 5 years later.
Coming back to the emissions test, you mentionned that you had failed these despite the fact the cat was in place?
Before passing the test did you fine tune the AFR with a sniffer in the exhaust?
In case you will no longer use the cat setup would it be for sale?
 
About time you do a build thread! I know it has been a rough road, but your luck will be changing for the better it sounds. Your mod list is impressive!! Can't wait to see the final results.

Thanks, I'm very excited, anxious and nervous :biggrin:

I know, been a little slack, i still need to post pictures but couldn't upload direct from the apple photo's.

I wish you the very best for the project!
Here in France, the "specialists" are no better than in the UK I believe.
One of my friends had his turbo kit installed by a "reputable" shop that resulted in a cracked sleeve as they tested the engine at 500 rwhp on standard internals...
For my own LoveFab turbo kit install, I went to a Honda official dealer who did the mechanical part while I did the tuning through emails with Cody.
Still working fine 5 years later.
Coming back to the emissions test, you mentionned that you had failed these despite the fact the cat was in place?
Before passing the test did you fine tune the AFR with a sniffer in the exhaust?
In case you will no longer use the cat setup would it be for sale?

I could come over to France when it's done and put some miles on it.

Really keeping my fingers crossed plans pull through, so far so good.

Sorry to hear about your friends luck but great news yours is still running flawlessly.

Yeah it still failed. I'm not sure if it's different here in the UK. I have a adjustable FPR i was tempted to turn the pressure down to see if it helped but decided against it even if it was for a brief moment.

Cody made a custom exhaust system which the cat sat inline, it wouldn't fit other systems.

Hope things work out. That's going to be a nice motor when you are done with it!

Wondering why would you go fic on your first tune and not a full system like even the older ems?

Thanks, It was mainly down to funds at the time. Allot of guys run the FIC so was going that route until i could afford to go standalone. After a bit more digging i believe the FIC is fine on OBD2 cars but on OBD1 it's not such a good solution.
 
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