Re: TKat13's Mach1 Build Log
 

I soldered the wire that go into the module, better clamping for the bolts. This harness shown goes to the two pumps that will engage under boost.
https://lh4.googleusercontent.com/-S...o/IMG_2875.jpg

Picture before I dressed the wires, the relay on the bracket is to change the trigger from (-) to (+) as mentioned above.
https://lh6.googleusercontent.com/-S...o/IMG_2878.jpg

Mostly installed at this point, will test before dressing the wires. I know if I dress the wires before testing then something will be wrong.
https://lh5.googleusercontent.com/-K...o/IMG_2880.jpg

Wiring diagram I used for the trigger relay conversion.
https://lh3.googleusercontent.com/-q...o/IMG_2881.jpg

Of course, this is where I went to add the antifreeze, just to find I had a leak... so I am dealing with this now. :Flame:

Re: TKat13's Mach1 Build Log
 

Got the antifreeze leak resolved last night. 5 hours to remove 4 bolts to the oil/coolant adapter but only an hour to install. Two evenings involved, the 'install' evening was much easier as I found some tricks and was more mentally stable. :)

So, I can now confirm that putting a 99 cobra gasket to a Teksid block with an '04 oil/coolant adapter works fine. I have not added the antifreeze yet but I did pull a vacuum and it held the vacuum so I should be able to assume I will not have any more leaks.

I had to remove the down pipe and disconnect the hot-side at the header on the driver's side. The removal of the oil adapter was also required just to get to one of the bolts on the adapter. After beating this adapter and not wanting to ever do this again, I decided not to reinstall the cheap On3 oil adapter kit and ordered a new Canton 90 degree oil adapter, canton filter adapter and putting -10AN oil lines between the two using Aeroquip Startlite hoses/adapters, had some -10AN hose left over from the turbo oil drain so figured I would use it. This should fix a possible weak link that I had been worried about, but wow those Canton products are expensive! I will post pics as soon as they arrive, should be here tomorrow.

Goal is to start it up this weekend, keep your fingers crossed. :COOL:

Re: TKat13's Mach1 Build Log
 

The Canton relocator adapter and filter adapter came in yesterday. The relocator is much larger than the one I am replacing, I can just barely get it on the threaded pipe, 3/4 of a turn, then it hits the header. Since I do not want to remove the header, I am going to fabricate a wrench to slide in there and twist the bolt in the middle of the adapter. You can not twist it by hand as there are orings to prevent it from leaking. Well, you can twist by hand, but not when in the position on the block, not enough room.

Note to anyone doing this, just buy the good canton unit and install it before installing headers. Also, make sure you have the right gasket. This has been a PITA.

Here are some comparison shots, the Canton unit is well worth the money, much better quality.
https://lh5.googleusercontent.com/-W...o/IMG_2892.jpg

You can also see the size difference.
https://lh5.googleusercontent.com/-T...o/IMG_2893.jpg

Yes, the cheap one has a thread adapter in it.

Here is the filter adapter, also a Canton product:
https://lh6.googleusercontent.com/-D...o/IMG_2895.jpg
Another angle:
https://lh3.googleusercontent.com/-r...o/IMG_2894.jpg

Re: TKat13's Mach1 Build Log
 

Just FYI (if you already know this I'll shut up)

I am installing this same pump controller, and if you use the FPDM's output
instead of coming directly off the inertia switch you have to be very careful
which wire you (varying voltage output) use so your trigger voltage
doesn't drop to low and trip out the relay. Some guys are getting around
this in the tune, I have it somewhere and will dig it up if you want.

Info on that would be great.

Re: TKat13's Mach1 Build Log
 

Great reading here http://www.svtperformance.com/forums...actuation.html

Diagram here.. See Post #4 http://m.mustangforums.com/forum/sho...2433&styleid=8

I hope these help you!

Re: TKat13's Mach1 Build Log
 

Finally fixed the Antifreeze leak and installed the Canton relocate kit for the Oil/Filter. I loved the Canton relocator, makes installing it much easier to be able to rotate it exactly at the angle you want. Especially in such a tight location.

However, because it was so tight for space, I had to fabricate the following wrench, the curve of the handle came in nicely to clear the k-member bars and give it a bit more turning ability.
https://lh3.googleusercontent.com/-W...o/IMG_2906.jpg

Here it is installed, I went through 4 different brackets before I got it where I wanted it. Wanted to make sure it was installed higher than the oil pan.
https://lh4.googleusercontent.com/-p...o/IMG_2902.jpg

Finally got everything back to where I had it, no more leaks.
https://lh4.googleusercontent.com/-W...o/IMG_2904.jpg

I then had to readjust the exhaust, cat-back. No pictures as this is just mundane work. Also connected the shifter linkage. Lowered on the floor and ready for start-up.

Re: TKat13's Mach1 Build Log
 

She's alive!!!

Last night I decided to attempt to start the Mach. Bottom line, it started right up. Needs some tune work obviously as it will not idle but the Air/Fuel ratio is actually pretty good for keeping it around 1500 rpm.

As many may remember, I had an antifreeze leak, this means to fix it antifreeze soaked into some of the exhaust wrap. At the end of the video, you see steam. This is why I cut the start-up short, it looked like 'SMOKE', but after getting out of the car you could easily smell the antifreeze.

This is with the cut-out open, after it gets a tune I will post up a sound clip with the cutout open/closed as well as an idle clip.

Hopefully this link work, I posted on youtube but the sound quality was dramatically degraded, so this link is to Google+. (I thought they were related)

https://plus.google.com/u/0/photos/1...IGWrKKxwLmm5AE

Now for Manny to do his tuning magic. :gears:

Re: TKat13's Mach1 Build Log
 

Next on the list was installing the bumper and trimming the foam bumper support. Before I installed the modified bumper support I had traced the opening on the foam. I used a Sabre Saw to make the cuts, just c-clamped the foam to the bench and started to hack away.

Here it is installed.
https://lh6.googleusercontent.com/-y...o/IMG_2912.jpg

Another angle:
https://lh4.googleusercontent.com/-G...o/IMG_2914.jpg

This should give the most air potential possible behind the stock bumper cover.
https://lh5.googleusercontent.com/-s...o/IMG_2915.jpg

I then installed the bumper cover and headlights. Next on the list is to wash the Mach, it has gathered a terrible amount of dust!

Re: TKat13's Mach1 Build Log
 

Sweet! Can't wait to see the numbers it puts down. Sorry if I missed it but what fuel will you be using?

Re: TKat13's Mach1 Build Log
 

E85; I am sure my numbers will be lower than what I want, the cheap turbo, stock intake and stock throttle body will hamper it. As well as having a TH400 behind it. I plan on upgrading the intake setup later this year, but need to recoup some funds first. After that I will put a precision turbo on it. The only good thing is I should not have to revisit any of the other supporting items.

Re: TKat13's Mach1 Build Log
 

Minor update, just working through the bugs now. I had an oil leak at the filter adapter, the plug was slowly leaking, fixed this.

A couple of other items, of course it is always the leaks that get you.
1. Antifreeze leak at one of the freeze plugs, easy fix.
2. Exhaust leak where the hot side connects to the passenger header, ordered Vibrant Performance V-Clamps and will tackle this soon.
3. Transmission leak, looks like the trans pump is leaking, possible clearance issues with the bell house, so the tranny has to be pulled, adjusted (more grinding) and reinstalled. This one is irritating as it is a ton of work, I may pawn this fix to HPP as I really do not feel like pulling it out. To much going on at work to work on this part of it.

That is it, after tranny is fixed it will be get tuned.

Safe to say, I freaking hate leaks... sheesh..

Re: TKat13's Mach1 Build Log
 

Awesome, I love how you trimmed the foam, I never thought of that, when it comes to airflow, every cfm counts!! I also like how you kept PS cooler line, if I wasn't so lazy I would have done that instead of the hose bypass. You are so close Darrell, freakin leaks, thanks for sharing the build with us :3b:

Re: TKat13's Mach1 Build Log
 

Quick update, I worked the weekend fixing the exhaust leaks where the hot-side piping connects to the headers, I thought the passenger side was the only leak but once I fixed that side I could still here a leak. Turns out the driver's side was leaking as well. Nothing wrong with the kit, I just had to loosen the three v-bands and adjust and retighten until I got it right. Has to be perfect.

This lead me to the next leak. After all the hot side was resolved, I noticed there was another leak. Turns out one of the waste gates were not closing all the way. Took it off last night and saw that the waste gate was bad. This is where having cheap parts hurts. I am sure On3 would replace this with a better one as they have been very good with me but I decided to go a different route.
Here is the picture of the valve, you can see how the valve is not sitting in there evenly and when you rotate it is wobbles. Just a bad part.
https://lh4.googleusercontent.com/-t...o/IMG_2969.jpg

So, the other route includes buying a new waste gate, I went with a Turbosmart WG38 Ultragate. Much better quality and should be here tomorrow just in time for a trip to HPP. Eventually I will upgrade the remaining waste gate but will have to wait a bit. However, the other one is not leaking. Here is a marketing shot of the Turbosmart unit.
https://lh6.googleusercontent.com/-N...twastegate.jpg

Wish me luck. :wall:

Re: TKat13's Mach1 Build Log
 

I should mention that I did get a reply back from On3, they offered to swap out the waste gate at no cost. As I suspected they are supporting me as they always have. Bad parts happen, it is the way they are handled is what is important. I had planned on upgrading the Wastegate and BOV in the future so it is not that big of a deal, just put me on that road sooner than I had planned.

anyway, thumbs up for On3 on this.

Re: TKat13's Mach1 Build Log
 

Ordered my Waste gate on Amazon and got it the next day, installed it last night. I can say that the quality of the Turbosmart waste gate is incredible. Here are some pictures of the Waste Gate. It is so much smaller in diameter on the top that I have a ton of space between the AC compressor and the Wastegate now. Before you could barely see daylight between the two.

https://lh5.googleusercontent.com/-W...o/IMG_2972.jpg

https://lh5.googleusercontent.com/-H...o/IMG_2971.jpg

Valve is perfectly centered and has a nice mating edge to the fire ring.
https://lh3.googleusercontent.com/-l...o/IMG_2970.jpg

With fire ring dropped in, just fits perfectly, zero movement side to side.
https://lh6.googleusercontent.com/-u...o/IMG_2973.JPG

I will be buying another one soon and replacing the other WG.

The car has just been dropped off to HPP for the tune, they are going to work it in. Love that place!

Re: TKat13's Mach1 Build Log
 

Minor update:
All the leaks/bugs have been worked out, we had to pull the tranny to fix a leak that was caused by the aftermarket bell housing not allowing the pump to fully seal. Easy fix, just a pain to pull it out. So I let HPP do the deed, much easier on a lift.

While it was there and tranny out, I had them fabricate and install a head cooling mod, not sure why I left this off the list but that was the first thing that was noticed when they pulled the trans.

Hopefully, if the weather does not get to severe today it will go on the dyno for the tune. If the weather gets to bad then all the customer cars will need to be rolled into the shop for protection.

Post up your guesses on how much power it will put down? I personally have little clue since I am temporarily using the On3 70mm turbo, plan will be to update it later to precision when more funds come available.

The build is in this thread, I have not left out any 'magic' power, so if anyone wants to take a guess then go for it.

The good: Motor is fully built, heads are ported, turbo cams, more fuel than needed, 80# injectors, E85

The bad: Stock throttle body/intake, small turbo, power robbing TH400.

If all goes well, plan to max out the little turbo, not sure how much air it can move and move past the TB/Intake.

That should be enough to make a guess. At this point, I just want to drive the thing, it has been a long road.

Re: TKat13's Mach1 Build Log
 

The rain stopped over here. Looks to be clearing up, so hopefully you'll get some numbers and behind-the-wheel time.

Back from the dyno, had to cut it short because a freeze plug I put in the trans blew out, my fault , but got two pulls .

Both pulls were with the cutout closed. The initial pull set at 7psi made 480rwhp. Not bad for the first pull.

The second pull put down 525 tq and 511hp on 9psi. Here is the graph , took a quick photo of the monitor. Of course called it a day and will fix the trans leak.
http://img.tapatalk.com/d/14/06/13/evavere4.jpg

Re: TKat13's Mach1 Build Log
 

Quick update, I don't have the dyno graph yet but the last pull we were able to get 636HP and 566 Torque, the curve looks just like the one above, got to the HP level and just flat lined across. This was at 13# psi. I believe there is more left but I think I will play with it at this level and then go back once I am bored with this level. It spools up almost immediately. This was through the full exhaust as well.

I suspect I am approaching the limit of this little turbo but with a better turbo I am sure much more is possible.

There is only 15 degrees of timing in it at the moment.

We had to stop because of an exhaust leak came back at the header on the passenger side, HPP is fixing this now.

Re: TKat13's Mach1 Build Log
 

Great numbers man. I expected your car to do high 600s low 700s.

Re: TKat13's Mach1 Build Log
 

Thanks, we are not done with the boost just yet. Since it is just 13psi, I am sure there is some left in it. I suspect the combination of the small 70mm turbo and stock throttle body+ stock intake are not helping me. The TH400 robs it of more. So far, it has been ~10hp for every 1 psi bump just not sure how far I can push that china turbo. 13# seems pretty safe, I have heard others taking it to 18 but not seeing any difference when taking it to 20.

Once I recover (save more $$$) I will put a precision on there, but I will have to decide if I should go with a 76 or keep the ~70 size.

Also not sure how much the cutout will help, some say 35-50 but I have no idea.

Stopped by HPP today, they fixed my leak, of all things, the Vband clamp was to wide where it tightened down, put a different brand on there that was more narrow and leak fixed. Apparently it was a very big leak so hopefully this will help regain some power. :)

Re: TKat13's Mach1 Build Log
 

Awesome! .. those are still great numbers regardless..Bet thats a fun ride!.. post of some vids.

Re: TKat13's Mach1 Build Log
 

As some of you may know, I am fighting a cooling challenge. To be fair to this build log I thought I would include the issues here but it is being well covered by a thread in the Coolant area. Linked HERE

The bottom line, I am not overheating but I am running hotter than I want. I commonly see 220 and have seen 230. So, a re-work is in order.

I am going to try a few things and will keep this log updated on the changes.
First will go with an inline thermostat in the upper hose, cap off the line that goes from the upper radiator tube by the alternator and install a GT lower radiator hose. This is to relocate a line that was running parallel with the down pipe. The thermostat will be a 170 degree.

If this does not help the issue, then I may be forced to re-evaluate my fluidyne radiator and/or change up the fan setup. Maybe dual 3300 cfm fans or add a push to the front of the intercooler/radiator area.

Finally, also considering adding heat extractors in my hood, but this will be a last resort. The Mach is a pure sleeper currently, this is what I like.

I will post pics of the changes along the way.

Re: TKat13's Mach1 Build Log
 

what was your setup before? stock? with the fluidyne ?