Official Sasquatch build thread Part 1, Cosmo Rotary Turbo... Then boom... Options

[Mike Bellis]

very impressive work thus far. i'm curious to hear how it sounds when you get to fire it up.

Thank You.

I'm so close to getting it running I can almost taste it! A couple more weekends of work and I'll be tuning the EFI. When I get it running I will post a video of it and you will all hear how good or bad it sounds. The part that sucks the most is the 500 mile break in for the clutch. No full throttle launches or it voids the warranty. 500 miles of stop and go traffic. (IMG:style_emoticons/default/sad.gif)

After that, I'm gonna hammer on it and see what will break... (IMG:style_emoticons/default/driving.gif)

I'm going to drive it for a year before I paint it. Unless I win the lottery (IMG:style_emoticons/default/biggrin.gif)

[Mike Bellis]

Got started on the plumbing to the intercooler. 3/4 fittings and hose. Found a cool inline filler so I don't have to go into the fender to top it off. I still need to source a pump. May hit up pick n pull for a BMW pump (Thanks Strawman). I picked up 5 quarts of Red Line Water Wetter today. I will fill both cooling systems with it. I've used it before and it works great. Royal Purple, Purlpe Ice works good too.



I pulled a gromet from my parts car and ran the hose through it. This is the one behind the dash normally for the heater controls. Just cut the inner hole bigger.

[Mike Bellis]

This engine requires a oil catch can/ oil breather. I searched online for one but didn't like what I found. I made this one from a scrap of 3" tubing. I welded on nuts and then drilled and tapped tham for 1/8 NPT fittings. The top connects to the air inlet right near the air filter. The bottom drains to the engine. The side connects to the oil filler tube. Welded on a bracket and painted it with "chrome" paint.

[Andyrew]

Which chrome paint did you use? Progress looks great!

[Mike Bellis]

Which chrome paint did you use? Progress looks great!

Dupli-color. It looks more like polished aluminum than chrome. Great reflectivity though.

[Mike Bellis]

I went to the junk yard today to pick up some BMW pumps. I told them they were heater control valves but they said they were water pumps. I guess they're smarter in Fermont than Sacramento at pick n pull. I ended up with 3 Hella pumps. I relocated my Radiator overflow tank to make room for my heat exchanger tank. The tank is T'ed into the pump inlet. The other side of the T is to the heat exchanger. The pump outlet pushes to the intercooler. The intercooler pushes to the heat exchanger. The inline filler has an over flow line that I connected back to the tank. I drilled 3 small holes in the first stage of the cap to allow air/water to flow back to the tank. This allows the system to self bleed back to the tank. This way the air will work out of the system automatically. I ran the pump for several hours with no problems. I used my Fluke lazer thermometer to get some readings. The radiator hose was 130F in the sun. The intercooler hose was 85F. They are positioned right next to eachother. The radiator has no fluid yet so the test was not completely fair but I do think the system will work well. The radiator overflow tank has been moved to the trunk. I punched a hoe in the floor for the fill connection and ran the hose under the car back to the connection at the radiator filler. The intercooler has been finalized and the pressure tubing is connected.



Here you can see the bottom of the overflow tank and the starter installed. I ran a 4/0 power cable from the disconnect up front. I then ran a #2 to the power terminal on the firewall to power my rear fuse panel.

[Mike Bellis]

Here is a shot of the radiator overflow tank. I'm not happy about its location but I ran out of room in the engine bay at the elevation I need. I think it will be OK due to the gasketed screw on lid.



Here is a money shot of the engine bay. Everything else fits good. The only available room is too close to the turbo. I could have mounted my overflow bottle there and it would be OK as long as it had water in it. But if it ever went dry in would melt. I'm down to a little wiring, fluids and tuning. My WB O2 module should be here this week so I can finish the wiring. Then tripple check all the hoses and fill the systems and bleed. Almost there...

[JRust]

Awesome Mike! I can't wait to see that sucker on the road. I'll be a little closer to your neck of the woods this weekend. I'll be in Monterey thursday-sunday. Just wish it was up & running so I could go for a ride. I will be flat towing the LE down so I can take off from my wife's family reunion. If your in the area at all give me a call (IMG:style_emoticons/default/beerchug.gif)

[Andyrew]

Which chrome paint did you use? Progress looks great!

Dupli-color. It looks more like polished aluminum than chrome. Great reflectivity though.

I've used that stuff!

Everything looks really great so far! I really like the BMW pumps.

[Mike Bellis]

Here's is a pic of my new oil cap in honor of Dr. Evil and his proctology expertise.



Here is a pic of my HKS blow off valve. Plumbed and ready to go!

[Mike Bellis]

Another random pic of the intake and peripherals...



You can see some of my 3" pressure tubing to the intercooler in the background...

[Mike Bellis]

Here is the best sticker... For those that dare let me pass...

[Mike Bellis]

Has anybody seen my license plates? They seem to be missing... (IMG:style_emoticons/default/sad.gif) I took them off in November and put them in a safe place. So safe, I can't find them...

[Andyrew]

I see water injection? Did you mention that earlier? Probably, I must have forgot..

Its looking Really good!! Love the oil cap. (IMG:style_emoticons/default/ohmy.gif)

[matthepcat]

Nice! Love that mirror sticker:

Rocking it on my suby.
(IMG:http://www.914world.com/bbs2/uploads_offsite/img839.imageshack.us-11125-1310516062.1.jpg)

[Mike Bellis]

I see water injection? Did you mention that earlier? Probably, I must have forgot..

Its looking Really good!! Love the oil cap. (IMG:style_emoticons/default/ohmy.gif)

No water injection yet. The blue hose is on the inlet to the turbo for the PCV oil breather system.

My Haltech WB O2 showed up today. Looks like I can start tuning in the next week or so. I have to finish some minor wiring to my gauge sending units. And double check everything.

I'm almost scared to start it. All this work over the last 9 months and now I'm almost done. If it doesn't work I will be verry dissapointed (IMG:style_emoticons/default/sad.gif) But if it does work, it's going to be a blast. I told my wife she can drive it on the road while I fine tune it on my laptop. At some point I plan on dyno tuning as well. I have to get it close first.

[Andyrew]

Ahh. Gotcha.


You'll probably be fine! just keep a fire extinguisher on hand and listen carefully!

Do they have any break in procedures?

[Mike Bellis]

You'll probably be fine! just keep a fire extinguisher on hand and listen carefully!

Do they have any break in procedures?

I've got 5 extinguishers ready!

Break in:
Pull plugs
squirt oil in the chamber
crank engine
prime oil system
check for leaks
install plugs
connect ignition
connect fuel pump
crank engine and hold on.

It's a JDM engine with 40-50kM on it. I'm absolutly sure it will need a rebuild sooner than later. Time will tell. If all the internals are good, there is a guy on CL that rebuilds them for $900. He's local.

I am also pre-mixing some 2 stroke oil in the fuel for added piece of mind. If the oil injectors work correclty with my electronic control unit (not my ECU) then I will not pre-mix again.

[Mike Bellis]

Got my Haltech dual wideband O2 controller installed. I am only running one sensor right now but I have the option for another. This is the same unit as the Autometer one just re-packaged. The Autometer version is cheaper and comes with a gauge. Wish I knew that before I bought it (IMG:style_emoticons/default/mad.gif) I will finish up the wiring this weekend after I help Jeff and Lennie get a -6 running. There is a slim chance my car will run on Sunday, July 17th, 2011(I'm setting a goal here) I suspect it will take a couple of days to get it tuned enough to drive it more than around the block. I decided to drive it to work for a week to break in the clutch. 90 miles total per day and mucho traffic both ways. The only time I get to go over 60mph is on the San Mateo Bridge. Once it is tuned enough to drive and break in the clutch... Then I will schedule some dyno time to get the fine tuning completed.



Standard Bosch 5 wire O2 sensor...

[Lennies914]

You're a hell of a guy Mike. I would have a hard time going to help someone else when you're sooo close. But I guess that's just what we do. (IMG:style_emoticons/default/beerchug.gif) Can't wait to see and hear the car. You're doing an awsome job. (IMG:style_emoticons/default/first.gif)