Joel's BRZ - Low Budget Time Attack Build

[DIY]

Speaking of DIY, yesterday I made this adaptor to mount my Bosch DBW throttle body to the new intake manifold.





It turned out pretty neat and now I can finish making the cold side tube to connect it to the intercooler.

[SuperTom]

Originally Posted by jflogerzi

Low Budget cause he is doing all the work himself which leave room for quality parts.

Oh I get it. I wouldnt have half the mods on my car if I was paying someone to do the work.

Joel the intake looks amazing by the way

[RuyGuy2]

I really just can't wait to see this thing on a track somewhere. I'm in awe of your commitment and investment of time into your car.

[ballsdeep]

Epic build, the role model for all K series swaps!

Do you have a clever idea for a cold air intake or airbox??

[DIY]

Originally Posted by ballsdeep

Epic build, the role model for all K series swaps!

Do you have a clever idea for a cold air intake or airbox??

Thanks mate.

I haven't put these photos up on here yet but I already have made a 4" pipe going into the turbo, I had to use some tight radius bends to clear the steering linkage. On the other end will be a large pod filter inside some kind of box that will take fresh air from the front bumper.

[Wrecky_Flowers_]

What valve cover is that? Loving this build!

[DIY]

Originally Posted by Wrecky_Flowers_

What valve cover is that? Loving this build!

It is actually the standard K24 cover but I cut it up and welded it back together to replicate the Honda HPD covers.

[DIY]

I have finished all the intercooler and turbo plumbing now.



Part of the reason I changed to a center feed intake manifold is that it moves the throttle body away from the front of the engine and as you can see in the photo below I now have unrestricted space behind the radiator for a fully ducted hood exit.



Next thing I'm doing is to replace the firewall in the engine bay. I've bought some big sheets of cardboard for making templates, then I will have to remove the engine and weld in the sheet metal based off those cardboard templates.

This video is a pretty good overview of where the car is at now
https://www.instagram.com/tv/CedWQES..._web_copy_link

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[DIY]

Just a small update for you guys.

I have mocked up the replacement firewall using cardboard templates. Removed the engine and now I am busy transferring those templates over to sheet metal to be welded into the car.

Removing the engine is fast and easy with the way I have designed everything.

[DIY]

I've had a bit of a break from working on the car but yesterday I spent the day turning my cardboard templates into a steel firewall. I don't really have much experience working with sheet metal and I don't have any tools for it either but I'm pretty happy with how this is coming together.

Just a video of the process for now, I'll get some photos once everything is complete.

https://www.instagram.com/reel/CheY7...d=MDJmNzVkMjY=


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[DIY]

Some more work on the firewall replacement today. I have now finished cutting and bending all the sheet metal so now it's just a matter of welding it all in place.



I ended up using more than one piece of sheet metal to do the tunnel replacement, simply because it's easier to manipulate smaller pieces rather than one big complex shape.



I found that even if my cardboard template fits perfectly there was no guarantee I would be able to make the steel bend in the same way, at least with my skills anyway.

[DIY]

Time for an update.

The firewall is finished. If you are late to the game the reason for the new firewall was that I am allowed to move the motor back 51mm behind the original firewall under the WTAC rules.

The original firewall was cut out, the engine was mounted in its permanent position, cardboard templates where made with the engine in place and then a new firewall was made based on those templates.



I used a plug weld technique to attach the new sheet metal basically mimicking the original construction. It was a lot of drilling around all of the perimeters. I used a weld-through primer on the back side before doing the plug welds with my MIG.

After welding there was a lot of grinding with a flap disc to give a smooth finish but I think it came up really good.



The whole lot has been primed now to prevent any surface rust while the build continues.



Here is a video of the inside and out

https://www.instagram.com/reel/Cjw7d..._web_copy_link

With the firewall finished I am moving on with the front pushrod suspension. I have purchased all the rod ends and bearings for the bellcranks and pushrods. A friend at work has been putting my bellcrank design into Fusion360 so we can first 3D print the bellcranks for testing and mounting and then later have them CNC machined from aluminium.

[DIY]

A little streamlining of the wheel well exits to help the air evacuate. After doing all that sheet metal work on the firewall I figured now was the perfect time to finish this job.



Both sides came out really nice.

[DIY]

I have been working on the front pushrod suspension. The design I made for the bellcranks have been transferred into CAD software and then 3D printed by my friend at work. This allows me to fabricate shock mounts and bellcrank mounts on the main frame rail and also the pushrod mounts on the lower control arms.

Some revisions will be made and this is the beauty of 3D printing them first but eventually they will be CNC machined from aluminium alloy.