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Old 01-01-2014, 12:29 PM   #101
JRCEngineering
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Re: TKat13's Mach1 Build Log

Just read the entire thread. Awesome! Cant wait to see the results.
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Old 01-02-2014, 02:23 AM   #102
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by lcaptmorg View Post
Awesome work. Thanks a ton a head of time for all the work you have put in posting up pics. Im sure it is a ton of help to many of us.
Thanks; as much help as I have received from reading this forum I figured I could return the favor. Maybe it will also help others properly budget their builds as I am trying to document all the 'little' things that come up.

I am sure there are better ways of doing some of this stuff, I am learning as I go. I have been told by many that I am crazy for even attempting this, maybe they are right. Posting in the forum actually helps keep me motivated, there have been many nights where I stare at the car is disarray and ask myself what the heck was I thinking. But, I am on the home stretch now. Certainly a balancing act between budget, garage time and family time.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-02-2014, 02:26 AM   #103
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by JRCEngineering View Post
Just read the entire thread. Awesome! Cant wait to see the results.
Thanks! I am not expecting tons of power with the first tune as I will be using a small 70mm turbo, but it is getting built to handle a bigger turbo down the road. Ultimately, I will put a 76mm on it and crank it up but for now I focused my attention on the core items. Swapping out to a better turbo will be cake compared to all the other items. I too am curious to see how much that small turbo will do.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-02-2014, 02:46 AM   #104
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Re: TKat13's Mach1 Build Log

Here is the parts list for the hydraulic pump pressure side hose build since I cannot purchase one. Thinking about it, I like the idea of changing to this hose style anyway since that hose runs pretty close to the turbo piping.

All this is at Summit Racing

1. Aeroquip FCU0606 - Aeroquip -6AN Startlite Racing Hose 6ft - 45.00
2. Aeroquip FBM4432 - Aeroquip Reusable Hose Ends 90 degree -6AN - 18.97 each, need two
3. Fragola Performance Systems 460616BL - Fragola Performance Systems AN to Metric Adapter Fittings, -6 AN Male Threads, 16mm x 1.5 Male Threads - 4.97
4. Fragola Performance Systems 460618-BL - Fragola Performance Systems AN to Metric Adapter Fittings, -6 AN Male Threads, 18mm x 1.5 Male Threads - 4.97

Tools, I am always looking to expand my tools.
1. Summit Racing SUM-900106 - Summit Racing® AN Hose End Wrenches - 9.97
2. Aeroquip FCM3661 - Aeroquip Vise Jaw Insert Tools - 21.97

This should do the trick, if anyone thinks it is a bad idea please let me know, otherwise I will let everyone know how it goes at some point.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-03-2014, 03:45 PM   #105
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Re: TKat13's Mach1 Build Log

Started test fitting the Hotside of the turbo kit. The 70mm turbo looks tiny once installed. The piping actually fits perfectly, now I get to pull it back off and wrap it up, copper rtv the connections and re-install. But before I do, I will test fit the cold side and the exhaust. I plan on putting in a cut-out on the down pipe so I am thinking best solution for that right now.

AC lines will be repositioned after I remove the piping from test fitting.


Passenger side piping, don't mind the rusted rotors, the car sat outside for 3 weeks while I was working on the motor. Glad I painted the non-touching surfaces.


Sway bar is not really that close, it is camera angle trickery.


Here you can see I was just starting on the cold side tubing but decided to call it a night as it was getting late.


Will be rerunning some wiring to keep it away from the piping.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-03-2014, 04:23 PM   #106
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Re: TKat13's Mach1 Build Log

Keep up the good work man! And yes, you're crazier than a bat in a bell-tower for doing this in your garage. Haha
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Old 01-03-2014, 05:36 PM   #107
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Re: TKat13's Mach1 Build Log

Looking REAL good man!

Side note: Am I the only one that looks at the name of this thread and think of adding a Star date to it?? "TKat13's Mach 1 Build Log, Stardate ______"

Maybe I'm the only nerd here though.

Keep up the great work man!
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Old 01-06-2014, 11:38 AM   #108
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by 311-420 View Post
Keep up the good work man! And yes, you're crazier than a bat in a bell-tower for doing this in your garage. Haha
Ha, I never thought of it that way...

Quote:
Originally Posted by ModMike View Post
Looking REAL good man!

Side note: Am I the only one that looks at the name of this thread and think of adding a Star date to it?? "TKat13's Mach 1 Build Log, Stardate ______"

Maybe I'm the only nerd here though.

Keep up the great work man!
Thanks, now I cannot get 'Stardate' out of my head.

Did not get much done this weekend, went to a State Park and played with fire instead. But, I did get a couple of more items test-fitted. Some of this has gone so well that I wish I would have just installed it, but I know test fitting is the proper method.

Piping to the Cat-back, don't mind the driveshaft, it is only connected at the transmission so it looks lower than it will be.




I will add the next pipe picture tonight, I forgot to snap a picture but it fit well. However, I will be making some modifications to the next pipe as I will have a 3" cut-out at the down pipe, figured it was cheap HP when you want it. It will be an OTP electric cutout.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-06-2014, 11:40 AM   #109
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Re: TKat13's Mach1 Build Log

Never took pictures of the drive shaft, here they are:
This is the end that goes to the TH400:


Here is the end of the rear end.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-09-2014, 10:41 AM   #110
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Re: TKat13's Mach1 Build Log

Button up the drive shaft last night, simple, locktite 'red' and two u-bolts and done. The part number for the Diff connection is from Moser, PY088, it is supposed to be much stronger than stock.


Next on the list was to start working on the intercooler placement. I will first state that the intercooler placement should be dictated by the piping, not where 'you' want to mount it. Yes, you have some play but life it much easier of you just let the pipes to the thinking.

I removed the bumper brace to make this job much easier. I then removed the brace that goes from the bottom of the hood latch to the core support, I am still thinking how best to replace this with a custom bracket.


Then finally I removed the hydraulic cooling tube. Just remember, even though you 'think' you've drained all the fluid out of the system, you will be proven wrong when removing those lines. I prepared myself by having the bucket near.

fuzzy picture so won't attach, but it showed the lines disconnected. Those things were really hard to pull apart.

Now was time for the piping, I started with the driver's side just because it seem more simple at the time. Once I had the driver's side piping connected, I placed the intercooler on a transmission jack to help hold it in place, this worked really well.


Now on to the Passenger side, started at the motor with the long inlet pipe.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-09-2014, 10:48 AM   #111
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Re: TKat13's Mach1 Build Log

This is the piping that the driver's side connects to, I forgot to include it in the post above:


Then I worked my way down towards the intercooler, two pipes left.




All is now test fitted, will mount the intercooler and notch the bumper bracket and then remove all the parts and apply RTV Copper and remount it.

Everything so far has just fitted with little effort, so far I am not sure what all the fitment complaints have been about. I am sure I will come into some at some point. Very happy so far, I also know this is not a high dollar kit so it is possible my expectations are not as high as others. But, I have been very impressed so far.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 01-09-2014 at 02:38 PM. Reason: grammer
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Old 01-09-2014, 10:52 AM   #112
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Re: TKat13's Mach1 Build Log

Man that looks sweet, I wish the ProCharger intercooler was that size, what a beautiful fit..well played!!
Why are the letters upside down???
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2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
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Old 01-09-2014, 12:51 PM   #113
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by not a gt View Post
Man that looks sweet, I wish the ProCharger intercooler was that size, what a beautiful fit..well played!!
Why are the letters upside down???
Thanks, I can only blame the Chinese for the letters, trust me it had me scratching my head, both sides are like that. If I had to apply logic, maybe this intercooler is used on other kits that has the piping on the top. This is their upgraded 4" deep intercooler.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-13-2014, 09:06 PM   #114
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Re: TKat13's Mach1 Build Log

This weekend the goal was to permanently mount the intercooler and modify the bumper, below is my story.

The On3 kit basically gives you the lower mounting support brackets, I was not satisfied with the stability of only mounting from the bottom. The intercooler has mounting bosses on the top as well so I took good use of those. It was very simple to utilize that area. However, I wanted to make sure whatever brackets I used could not be seen through the open grill.

I located the metal tabs that the header panel mounts to, I used the lower tab. Created some 'L' brackets with a twist, literally. The brackets ended up being 6" x 3".

Placed in vise at location of the bend.


Lightly applied pressure at the top of the bar and lightly tapped with my hammer, bar just easily bent down.




With the mounting angles of the two locations I had to add a slight twist to the bracket:


Drilled mounting holes, painted and installed. I put one on each side.


With both mounts, the intercooler is extremely rigid. With the plastic cover and even via the front grill the brackets cannot be seen.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-13-2014, 09:14 PM   #115
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Re: TKat13's Mach1 Build Log

Now with the intercooler mounted on it own, I noticed the hood latch seemed a bit flimsy as I had to remove the support rod because of the intercooler. I quickly applied the same logic above and modified the factory support rod.

Added a bend in the middle where I flattened the rod and then marked the new mounting location, flattened it and drilled a new hole. Quick spray of paint and rod is complete.


In location:


Again, cannot see the support bracket via the grill or above.

Now the Intercooler is completely mounted, next on the list was to modify the bumper support.


One thing to note, I have the 4" core instead of the standard 3" core, which means I needed to notch the back of the bumper and also cut the front. Silver Sharpie is your best friend when working with black material.
Front:


Top:
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-13-2014, 09:19 PM   #116
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Re: TKat13's Mach1 Build Log

Most of the cutting was really quick with the Grinder loaded with a cutting wheel.


Top:


After the cutting, obviously this bumper support was extremely flimsy, so I decided to add some rigidity to it by welding in a bar.




Sorry, not that good of a welder but they will hold.

Took this chance to mark the foam bumper support where I need to trim.

Put it on the finished bumper support and traced the lines.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-13-2014, 09:23 PM   #117
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Re: TKat13's Mach1 Build Log

Quick splash of paint to prevent rusting and mounted the support. This part is finally done!


The next project will be to create a dump on the down pipe, the plan here is to run full exhaust around town to keep things quite, and then later open her up for racing. The last part will be to add an electronic dump valve, but for now I will just cap it. The QTP dump will bolt right up to the flange that I plan on using. This will be my first attempt at welding on Stainless Steel, 304. I guess there is a first for everything...
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-19-2014, 08:44 PM   #118
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Re: TKat13's Mach1 Build Log

Nice work so far. Very interested in how it turns out. As a guess my skill level with the MIG is similar and I've been able to weld stainless steel. Heat can distort the part so keep an eye on that. For exhaust tubing it might not be much of a problem.
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Old 01-20-2014, 04:07 PM   #119
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Re: TKat13's Mach1 Build Log

Looking good!!
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Old 01-27-2014, 05:36 PM   #120
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Re: TKat13's Mach1 Build Log

I've been on the road for work that past few weeks so not much has been done. However, I was able to weld on the cut-out, not as good as I wanted but I guess it will do the trick for now. I may opt to do a custom down pipe later when I swap out to a bigger turbo, assuming I will not meet my horse power goal with this one.

Before you ask, I have spend a ton of money and the new turbo was always slated for a future upgrade after I get all the other supporting mods done.

Here is the area marked for the knife on the down pipe.


And cut, I left some overage to help me not blow through while welding, it did the trick.


Part going one:


Test fit, it is very close, if I had to do it again I would extend the cut-out further down, the plan was to mount the cutout switch/valve and then and extender from there to protect the butterfly valve from bumps. The reason is past experience with a buddy's car where is was low enough that he has bent his butterfly valve.



I then took it off and started to wrap everything with titanium exhaust wrap from DEI.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 01-27-2014, 05:38 PM   #121
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Re: TKat13's Mach1 Build Log

Here are the other hot-side pipes I wrapped, I made a big mistake, I did this without gloves and wow my hands were itching. I guess there is fiberglass in those wraps... oops.





Out of 100ft, this is all I have left:
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 02-17-2014, 01:09 PM   #122
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Re: TKat13's Mach1 Build Log

It has been a while since I updated the thread, things are going pretty slow, but this is because of my work schedule.

I completed the piping to the intake, I decided not to use the stock On3 piping going to the throttle body. However, I did use the On3 intake piping as parts. Here is the test fit with pipe cut and shoved into the C&L.


I marked the direction and top, then took the pipe down to HPP to have the Maf flange welded on, I had it placed at the bottom. The wiring was all plug and play as I just purchased a pig tail.


Next I test fitted, marked and painted the tube wrinkle finish.


Picked up a Vibrant Performance 3-3.5 Silicone Reducer and connected the pipes. I still need to buy T-Clamps for the rest of the C&L intake.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 02-17-2014, 01:24 PM   #123
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Re: TKat13's Mach1 Build Log

I have finally mounted most of the hot-side up permanently. I only took one picture of the copper sealant, figured the rest would be redundant anyway.



Here is a quick picture of both hot side pipes connected, for the keen observer the AC Line is not the factory line that came on the car, the filter was black and this one is silver. I poked a hole in the line when installing the radiator, but it later proved to be where my really small leak was coming form, I just finished it off.

Anyway, the point here is this line is a Motorcraft brand, but at some point they put a 90 degree bend after the end of the filter, this was absolutely perfect as with it in the stock location it was hitting the turbo, with the 90 degree bend it gave tons of space back.


The small problems are what takes the time to solve and implement. I needed to re-wire the fan because I the wires were to short for the path I wanted them to run. Wanted to clear the turbo better. Soldering 10 gauge wire is a pain!


Here is soldered and heat shrinker.


I then wrapped the wire in loom and DEI high temp covering to reflect the heat form the turbo. I also had to trim the fan housing. I should point out that all of this trimming is because I have a large aftermarket radiator and is proving to be a PITA.


Later, the pictures will show the thermostat resistor connection. In all, I added 4 inches to the main power, and 8 inches to the resistor connection.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 02-17-2014, 01:33 PM   #124
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Re: TKat13's Mach1 Build Log

Very nice and clean...any plan to wrinkle finish black the C & L pipe?
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2003 DSG Mach 1-03 Cobra Term/T56 swap:
2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
Tuned by B.Kurgan
601Hp/558/Tq
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Old 02-17-2014, 01:33 PM   #125
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Re: TKat13's Mach1 Build Log

Before I mounted the turbo, I installed the oil feed and drain connections. The drain line is being upgraded to Aeroquip Starlite hose, I prefer to have a solid hose and this is good stuff, but the fitting barely fits.


Turbo installed, you can also see the upper fitting installed, oil feed:


First waste gate installed, I had to notch the bracket for the ABS brakes, it was barely touching but took enough material to allow movement. Eventually I will replace with a non-abs block.


At this point I contacted On3 about spring options, they are hooking me up with a stiffer spring at a great price. They have been very helpful.
__________________
Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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