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Turbo swap I am working on.
http://forums.ctzcc.com/viewtopic.php?f=4&t=6294		 Page 1 of 2
Author:  CygnusX1 [ Fri Sep 02, 2011 2:49 pm ]
Post subject:  Turbo swap I am working on.
I have been working on this project all Summer, on and off, but yesterday she fired up. This is Fred Maurer's long awaited turbo swap. He approached me about 6 years ago, when he saw my turbo Z at Bear Mountain, and always wanted to do it himself. Over the years, he gathered all the parts, but he never got to it. This Spring, I offered to get the ball rolling for him, and to get it done over the Summer. Here are the project photos. You may recall the ZX Turbo car I was parting out a couple of months ago...

She should be rolling in the next few weeks.

Yes, it's a real ZAP.

PROJECT GALLERY:
http://dcer.smugmug.com/Other/Turbo-Swa ... 28_7rXdC4q

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Author:  PhrogZ46 [ Fri Sep 02, 2011 4:03 pm ]
Post subject: 
Nicely done, looks really clean. no intercooler though... :(

What fan did you use? Is that an electric or the stock shroud and mech fan bolted up to that aluminium rad? I'm having a heck of a time figuring out what I'm going to fit on my Koyo rad. Very tight clearances, and no provisions for the stock shroud.
Author:  Frank T [ Fri Sep 02, 2011 7:27 pm ]
Post subject: 
Phrog, consider electrical push fans from in front of the radiator.

Dave, I'm moving this over to TECH TALK because it looks like an excellent thread for learning/teaching stuff.

Frank
Author:  CygnusX1 [ Fri Sep 02, 2011 10:54 pm ]
Post subject: 
The radiator is the 3 row core, available on ebay as a "Champion" brand. The shroud is from the 77, the fan is from the 82. Nothing lined up perfectly. In order to make the shroud mount central to the fan, I had to drill new holes in the shroud, and new holes in the radiator mount ears. It took some figuring to get right, but it works. I basically had to raise the shroud, and raise the radiator. Hopefully, the cap clears the hood!

No intercooler because this was commissioned to be a stock for stock swap. In all honesty, I strongly believe that swaps should be completed as a stock-as-possible project, and then modified after initial debugging.
Author:  PhrogZ46 [ Sat Sep 03, 2011 1:51 am ]
Post subject: 
Frank T wrote:
Phrog, consider electrical push fans from in front of the radiator.

Dave, I'm moving this over to TECH TALK because it looks like an excellent thread for learning/teaching stuff.

Frank


Already did. Idea was tossed because of insufficient room between the radiator and intercooler and that pusher fans can cause decreased cooling efficiency due to impeding air flow when not in use (when car is at speed).
Author:  Frank T [ Sat Sep 03, 2011 8:42 am ]
Post subject: 
Bryan researched and sourced the dual off-set, skinny electric fans from a certain year Volvo station wagon (I think) for his Z. He knew exactly what he wanted and searched until he found one. He sandwiched it into the skinny space available after he modified his own 240. It works great. He ran it by handswitch for years, and only recently converted it to autoswitch.

Frank
Author:  CygnusX1 [ Sat Sep 03, 2011 9:47 am ]
Post subject: 
On my turbo swap I have a multilayer sandwich up front. The layers are as follows: Intercooler, oil cooler, A/C condenser, 3 core stock radiator, and Mr. Gasket 16" electric fan with temp probe and controller. The fan is cheap and very thin. I don't run a shroud other than what is part of the fan assembly. Just mount the fan center slightly offset from the water pump, to gain a bit of extra clearance. My car never overheats and makes a ton of power.
Author:  theZman [ Sat Sep 03, 2011 11:40 am ]
Post subject: 
Thats what I am going to do with mine. Just a stock swap then modify later.
Author:  Rich@RDZ [ Sat Sep 10, 2011 7:05 pm ]
Post subject: 
Looking Good
Author:  Kathy & Rick [ Sun Sep 11, 2011 10:05 pm ]
Post subject: 
:roll: When ya keep 'em stock and original,
ya don't have none of them there issues to deal with.
~Rick~
Author:  PhrogZ46 [ Mon Sep 12, 2011 12:17 am ]
Post subject: 
Kathy & Rick wrote:
:roll: When ya keep 'em stock and original,
ya don't have none of them there issues to deal with.
~Rick~


Working out the issues is a major part of the fun. Seeing something grow from a mass produced factory copy into something you've sculpted and constructed into something unique, it's something special. To know that you're the one who made the changes and ensured that it all works together in the end is the essence of the joy of creation. In a way, the car turns into something that is truly "yours" and becomes a part of you.

Much more so than other bits of the car's character that you influence, like that ding on the door or the cigarette burn on the console from when you missed the ashtray.
Author:  Kathy & Rick [ Mon Sep 12, 2011 7:47 pm ]
Post subject: 
I know you're right, Chris. I'm just bustin' 'em off!
~Rick~
Author:  mikeatrpi [ Wed Sep 14, 2011 7:42 pm ]
Post subject: 
Dave, it looks great!!
Author:  CygnusX1 [ Wed Sep 14, 2011 8:15 pm ]
Post subject: 
Thanks Mike. Finished the brakes today, and put the hood on. Uh oh! The hood won't close. :cry:

Apparently by trying to make the shroud work with the larger ZXT fan, and raising the radiator to comply, I ran out of head space. Now I need to re-do the whole radiator/fan/shroud thing. Rethinking....soon to be redoing. The owner of the car is going to help me solve this one.
Author:  CygnusX1 [ Mon Sep 26, 2011 6:44 pm ]
Post subject: 
Lowered the radiator back to where it was supposed to be and removed the fan shroud to make clearance for the fan. Now the hood closes. The car is all done. It's off to the muffler shop this week for a 2.5" exhaust system. Once it comes back, I'll spend some time shaking it down, and fine tuning it.

I spent some time with the orbital buffer today. Lots of oxidized yellow came off the paint.

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