projekt zeal86 (build thread)

[zeal86]

Originally Posted by JMoneyFRS

Looking good Zeal! We met yesterday, Justin from the zone....I'll have to check it out in person one day.

It was awesome meeting another enthusiast here in West Texas... Especially another zn6 enthusiast... I was beginning to think I was the only one. lol

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projekt zeal86 build

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[zeal86]

Received notification today that my Beatrush air intake duct has shipped... I'll know soon if I can modify it to work with my HKS v3 supercharger. If not, I'll go with the HKS air intake duct.

I really want this part to work out!

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projekt zeal86 build

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[zeal86]

Ran into a hiccup yesterday separating my front pipe at the over pipe union... so today I brought the tools I needed from work. Gave it a go today and I was able to break loose one nut on either side of the over pipe. The two that did not cooperate started to come off then got hung up so I sprayed PB Blaster on them... I'll try them again tomorrow.

If it weren't for the hiccups both front pipe and exaust manifold would have been easy swaps.

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[weederr33]

Originally Posted by zeal86

Ran into a hiccup yesterday separating my front pipe at the over pipe union... so today I brought the tools I needed from work. Gave it a go today and I was able to break loose one nut on either side of the over pipe. The two that did not cooperate started to come off then got hung up so I sprayed PB Blaster on them... I'll try them again tomorrow.

If it weren't for the hiccups both front pipe and exaust manifold would have been easy swaps.

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projekt zeal86 build

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When I did my overpipe and headers, talk about a serious pain in the butt. But with plenty of PB blaster, I was able to get it off. haha

[zeal86]

Originally Posted by weederr33

When I did my overpipe and headers, talk about a serious pain in the butt. But with plenty of PB blaster, I was able to get it off. haha

I take it they came off undamaged? Mine should not even be seized... hopefully the studs don't get stripped in the process. Crossing my fingers...

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[weederr33]

Originally Posted by zeal86

I take it they came off undamaged? Mine should not even be seized... hopefully the studs don't get stripped in the process. Crossing my fingers...

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Nothing broke or stripped, it was just a serious PITA. But since I had new hardware with the exhaust, I didn't really care if I would have stripped the nuts.

[zeal86]

Originally Posted by weederr33

Nothing broke or stripped, it was just a serious PITA. But since I had new hardware with the exhaust, I didn't really care if I would have stripped the nuts.

I'm more worried about the stud at the front pipe to over pipe union... it is inserted through the over pipe...I am not replacing that so I do not want to strip the threads.

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[weederr33]

Originally Posted by zeal86

I'm more worried about the stud at the front pipe to over pipe union... it is inserted through the over pipe...I am not replacing that so I do not want to strip the threads.

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Oh! I didn't know you weren't doing the over pipe. I guess just be careful. I didn't the studs on mine but it sure felt like I would.

[zeal86]

Got my front pipe and exaust manifold out today...the PB Blaster did it's job. One stud on the front pipe/over pipe union is a bit damaged but I think I can fix the threads.

The other pain in the a$$ nut stayed stuck and rotated the stud out of the exhaust manifold flange. Next up are the HKS spark plugs... then the installation of the front pipe and exaust manifold followed by prep work for the SC install.

There will probably be some cleaning and polishing during the rest of my installs... lol

Big weekend ahead!

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projekt zeal86 build

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[zeal86]

So I cleaned up the threads on the damaged stud. I am able to thread the nut all the way down by hand but it gets slightly hung up where the damaged threads were/are. I will try to find a new stainless steel stud this weekend because I would rather replace it.

I have read that others removed the heat shield to shimmy the over pipe out the back... I had success pulling it out the front...granted I have my exhaust manifold out.

So while the over pipe is out, I decided to practice polishing on steel. I am pretty good with aluminum but I haven't worked a whole lot with steel... especially steel in the condition of my over pipe. So far it is coming out pretty good...Depending on how successful I am polishing the over pipe, I might polish the steel supercharger bracket and hardware I was looking to powder coat. I'll post pics tomorrow sometime.

I hope to get my spark plugs in tomorrow... I'm going to follow the service manual instead of getting at them from the top.

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projekt zeal86 build

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[zeal86]

Spent more time on this then I had planned but oh well... f@#k it, it looks good... I will install it without the heat shield since the exhaust manifold will not have one either.

Before



By the time I took this pic I had begun to smooth out the outer edges of the flanges with a 40 grit Roloc. The edges were alot worse than what is seen in the pic.



Nicked up thread pictured here...I just replaced both studs even though only one was bad.



Half and half pics...





After







Stock over pipe matches all my other exhaust components now!



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projekt zeal86 build

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[NahumCC]

Looking good. I'll admit I cried a little when I looked at my engine bay today when my brother asked to see the car. It needs some serious time and attention to get rid of the dusty water spot look.

[zeal86]

Originally Posted by NahumCC

Looking good. I'll admit I cried a little when I looked at my engine bay today when my brother asked to see the car. It needs some serious time and attention to get rid of the dusty water spot look.

Just take a weekend to do the heavy cleaning then focus on the details the following weekend... Once you have that accomplished, wipe it down every 3 weeks to a month to maintain. If you do car shows, you won't be too far off from being show ready... or if you are just showing a friend or relative, you won't get sad... lol

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[zeal86]

I'm definitely going to get to my spark plugs tomorrow... once I get those in, I'll install my exhaust manifold and front pipe. Then it is on to the supercharger install...

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