Dustin's UltraMarine FR-S (Engine Blew - LS3 Time)

[Viper8]

Impressive work man, keep up the good work.

[DustinS]

Originally Posted by Viper8

Impressive work man, keep up the good work.

Thank You!

[DustinS]

Got some work done despite the crazy winds and being kind of chilly. Starter, Alternator, and Water Pump are installed. Some last minute wiring. Heater Hoses routed. Fittings on Expansion tank finished up and sealed.

This wire tie didn't turn out as well as I had hoped. Will be changing it.



Goes around back and is ziptied and wrapped to help keep it safe.



Everything needs a good cleaning. Bought a Billet Aluminum Alternator Pulley to replace the broken one. Still need to pick up hose clamps. I can't wait to switch to AN lines.







I also switched out the Nipple fittings for some -6an AN fittings and mounted the Catch Can.





I was going to start messing with the Steam port stuff, but couldn't find the box. Figured it was in the box of parts in the wifes trunk. So I waited until she got home... Couldn't find it. Fell out of the first box and was hiding behind other parts -_- . Could have installed those... Project for today I guess.

[DustinS]

Originally Posted by Grawlix

After all the setbacks and bulls#it, it's great to see this beast coming together anew. Very much looking forward to seeing that fire get lit once again.

Thanks! So am I.

Spent 4 Hours Getting 6 AN lines made. Seems like so little done for so much time. Most of the time was spent trying to 1: Figure out Steam Port Line configuration and 2: Getting the stupid -6an hose on the engine/intake side hose barb fittings for the catch can. Worth job ever. On to pictures!

Not impressed with the trickflow fittings. To start the bolts were too long and needed cut down:



The fittings were also very rough and didn't like to turn very well. I should have just pieced the kit together. I also found that the kit doesn't work too great with factory manifold.

General Overview:



The Catch can Lines match better than it looks in the photo.

Steam port inlet.







Had to buy some 45 Degree fittings to clear the Catch Can line. Running one on the other side just to look even.

Also contemplating putting the overflow tank here:



Run the overflow line through fender and into tank.



At this point. Not much to do other than finishing touches and stuff that require welding. So I may get the welder out and get the radiator mount done so I can make the radiator hoses. I also need to figure out how to mount the fans. I was planning on running a set of aftermarket fans, but at this point I will save that for a later date.

Picking up some satin black paint for the Expansion tank, throttle body, Valve Covers, Tensioner, and possibly alternator. Need to get an LS3 Thermostat as well.

[DustinS]

Got the thermostat and it seems to be longer. I don't remember my original being this different, but oh well. Thermostat housing on, so I can get the radiator mounted and begin making lines.

[DustinS]

Got quite a bit done. Unfortunately still a lot to go.

Manifolds are going to be a difficult project. One I may just take to a friends shop to have done.





Got the radiator mounted, and radiator hoses made. What a pain. I will need to do it again when I make a new passenger side hose down the road. I only order 90 degree fittings as that is what I needed, but I had the fittings changed on the radiator side and that changed the fittings needed.





The issues that caused the weird routing:



Lines finished up and tank painted.



Wiring/overflow line through fender is finished up. Overflow line may be too long, but I can deal with that later. With as much hose as I have, it will be easy to change.



Overflow tank w/ mount. Very simple and easy to get too. Thinking about painting this the satin black as well.



This is what the manifold looks like. Want to get it ceramic coated black.





More Paint:



Lower Radiator mounting tabs. Didn't want to have to take it to get welded. Will see how the JB weld Does.



Getting so close:

[DustinS]

Well the pulley I bought ended up being too small. So I am going to return it and just get a normal steel one.



Radiator is mounted. Rivnuts epoxied to the radiator for the slip joint. Bolted up top





Took off the throttle body to give it a little paint and wiped the intake out... Need to get in there a do a little more cleaning



Got all the loose powder coat off and just sprayed it black. Will be replacing later anyway, and they are hidden by the coil packs.

[DustinS]

Was pouring rain yesterday, but got a bit done anyway. Rear Brake parts were dropped off, and I got the water pump fitting re-sealed. *Hopefully*



Found my original Thermostat (On Left). I decided to run it instead just in case.

[DustinS]

Got the wiring harness installed, and one of the rear hubs installed. I then realized I don't have spacers/Extended studs for the rear... So with the chance of getting the car running this weekend, I am just going to drill my STI rotors to 5x100 to run my old hubs for this weekend till my new spacers and/or studs arrive.

Going to look great though.

[DustinS]

Well she came out and about for a bath and getting these 500 break in miles finished before a good Dyno Tune.





Still need to work on new ducting for the front, and new side blanks for the grill.



Caliper Brackets were milled out this weekend. My measurements were just a tad off, sat a bit too high. I feel like I had fixed this in my most recent files, so wondering if I accidentally sent the wrong file again. Oh well, easy fix. Just needs milled down.

[mistople]

This is awesome!

[laextreme5]

Those brackets are rad. What did you end up doing with the exhaust manifolds? What was the purpose again of running the rad tilted farther forward?

[DustinS]

Originally Posted by laextreme5

Those brackets are rad. What did you end up doing with the exhaust manifolds? What was the purpose again of running the rad tilted farther forward?

Thanks. Dropping them off during my lunch break to have them shortened and the rotor spacers made.

The LS7 manifolds are waiting for the couple more parts. I still need a few exhaust donuts for a super tight 3" bend, and a couple flex sections. I also need to figure out how to pass dual 3" around the diff section haha.

I tilted it further forward to help with ducting the rear of the radiator out the hood.

[laextreme5]

I remember seeing someone heated and distorted their factory fuel tank for exhaust routing around the diff.