My never ending project - AP1 goes stock(-ish) again (NA)
 

I apologise for a LONG post, but hope it's interesting to someone.
Well, I've had the car for almost 6 years now. Have done quite a few different mods through the years, but I think it's easier to just throw out how the car is now rather than start all the way from the beginning. :p/> To go turbo with the S has been only a wish until around September/October this fall (2011). I then sold my other car, a BMW E36 that I had just finished. The car was really good condition when I was done with. New 18" OZ Superturismo wheels, adjustable lowering kit, M3 front, sideskirts, removed all rust, painted the whole car ++. I was supposed to use this car as a winter beater, but didn't have the heart to drive it in the winter with all the salt they use on the roads here in Norway in the winter months. So I sold it, and bought a crappy car for a few hundred bucks from a friend. That's when the turbo plans became more realistic :p/> I suddenly realised I had about half the money for the kit itself. I could probably manage to get the rest in a few months so I could buy the kit and finish the project. And so I did :p/>

I bought the kit as soon as I could, and got it delivered in mid December. In about a week I had done most of the work.

Removed all the stuff I had to before the kit arrived, so I could get to work once it arrived.

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I like the look (and sound) of the HKS Hi-Power exhaust I already had, so decided to keep the mufflers and ditch the rest of the exhaust. I know I could have used the exhaust, but felt it was unneccesary to "restrain" the car more than I had to. So decided to build a new exhaust from the midpipe that came with the kit. Chopped the HKS:

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Finally started on the build! Moved the fuse box, bent the AC lines:

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Yeahj! Parts!

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Also had the driveshaft (think that's what you call it in English?) overhauled, as the joints had seen better days... Here a pic with the intercooler:

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A day (or two?) later. Almost done in the engine bay!

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Tight fit!

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Well, time to build new exhaust then! First polish the mufflers :)/>

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And off to buy some stainless steel piping and bends to make the new exhaust. I think the S2000 looks best with dual exhaust, so wanted to keep that. Went with 3" from the turbo to the diff, as the turbo has 3" outlet and the downpipe and midpipe also were 3". Went with 2,5" from where we split the exhaust.
A few pics from the exhaust build, from start to finished:

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Got the car tuned this Saturday, but need to find my cable so I can upload dynosheet and final engine bay picture :)/> Hope you enjoyed.


Edit:
A few specs

Engine: InlinePro F20C1 shortblock, 9:1 compression
Spark plugs: NGK BKR8EIX
Injectors: ID 1000
Fuel pump: Aeromotive A340 in tank, + Fullblown surge tank kit
OEM TB
Omnipower 4 bar map sensor
AEM V2 (30-6052)
Turbo kit: FullRace ProStreet w/ Garret GT3076R
Clutchmasters FX725 twin disc clutch

looks great! like the exhuast very nice piece.

What were the dyno #s? Nice kit/build. I will recommend you to put a heat shield between the manifold and battery/fuse box as the heat will take its toll on the components. In my case the battery wouldn't crank the car well when heated.

Thanks guys :) The numbers were 420whp and 420nm (309 lb/ft) at 13psi.
I had already made a heat shield, but it didn't fit in the end. So I'll have to make a new one. But I'm definately making one!

congrats, loving the manifold in that coating :thumbup:

Looks GREAT, love to see fabricated exahust componets like that, from someone who has done it I can know the time and effort it takes to do it right :thumbup:

One word of caution, that manifold is going to get REALLY hot, I would highly recomend you put a heat sheild over it. Sarek (Paul) was the first to use ATP's inconel wrap and it works very well. The link below has some photos of his Fullrace setup. Notice that he also tried to coat the manifold first but it was not enough to keep the heat in.


https://www.s2ki.com/s2000/topic/732...updated-new-s/

Thanks! Yeah, the exhaust took a lot of hours. I don't think I exaggerate if I say we used about 20 hours (two days) from start to finished on the exhaust.
And thanks for the tip on the ATP wrap. I will make a heat shield to put between the manifold and battery/fusebox to begin with. I have some gold foil left to use on it. Hope that will help. Really looking forward to getting to test drive the car in not too long! It was -22 degrees F this weekend.. It's about 23 degrees F now, but snow and wind doesn't help...

heat shield your hood above the manifold, my carbon hood cracked when using that manifold

Don't take the heat sheilding lightly!! I would really suggest that you relocate the fuse box and battery.

I melted my fuse box the first day after I got my car tuned...I had to ghetto fab a heat shield using my front license plate and a coat hanger that I found on the side of the road
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This is the first heat shield that I fabbed up (I only have basic hand tools). It worked ok, but snapped by the valve cover due to vibration.
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The first heat shield did not protect the firewall, so my AC lines (relocation kit) and my heater control valve melted!
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Here's where I'm at now..fuse box/battery relocated, heater control valve relocated (under wiper cowl), heat shield to protect hoses on firewall
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My hood right above the manifold still gets pretty hot, might have to address that issue come spring/summer.

Good luck with it!
Scott-

Thanks for the tips. I won't be able to use the car for about 5 weeks or so, so I'll look into making some heat shielding in the meanwhile. I had already made a shield between the manifold and battery/fuse box, but it didn't fit after all when everything was in place...