sutyak's turbo 2004 Mach 1 build thread

[sutyak]

Today I continue the long process of undoing so many of the things the last guy did to this poor car.

It looks like he cranked the coilovers down too far and burned up the fender liners. It also probably didn't help that the driver side liner had zero clips on it.


New ebay fender liner. Driver side fit fine. I ended up reusing the stock passenger liner because it fit better.


The CCRM (constant control relay module) was loosely rattling around in the fender well, held on by one zip tie.
This photo was the CCRM basically falling out after I removed the fender liner.


I removed the mounting bracket and more solidly zip-tied it to the cold side piping. Not where I wanted it, but it's secure now.


Speaking of cold side piping, he did just a stellar job (sarcasm) with widening the fender hole. This is also on my to-fix list. There is no flex to the piping. It's wedged there.

[sutyak]

At the end of the day I stand back and remember why I put in all the work. I really do love the looks of the Mach 1.

[not a gt]

Man, dude was a butcher

[sutyak]

Originally Posted by not a gt

Man, dude was a butcher

No doubt. I am so glad he didn't build the motor and tune it himself. At least someone who knew what they were doing handled the important parts.

[ASH302]

nice work, at least you are getting all the little things done up.
that fender part fit and looks nice in there.
my mach will always have a special place and I love when I see one.

ASh

[sutyak]

Making some progress removing old unused wiring and wiring up a fuel pump cutoff switch that will open the circuit to the pump relays.
I also picked up a 6 point MM roll bar with swing out door bars from a guy in Cumberland MD. It's never been installed and is even powder coated. His plans changed and he needs a full cage now.

[MachMyWords]

Excellent work. Even more excellent that I realized you were in Fairmont (I'm up in Morgantown). If you ever would allow someone to sit in those A4's and see if they like them sometime let me know, because I am on the brink of ordering some.

Keep up the good work and I hope to see this thing out sometime.

[sutyak]

Originally Posted by MachMyWords

Excellent work. Even more excellent that I realized you were in Fairmont (I'm up in Morgantown). If you ever would allow someone to sit in those A4's and see if they like them sometime let me know, because I am on the brink of ordering some.

Keep up the good work and I hope to see this thing out sometime.

Thanks. You're welcome to come by anytime. Shoot me a PM. I think I'm going to go ahead and install the roll bar and seats, and then continue with the transmission. You should stop by SteelCityMuscleCars.com for a local forum. We have a few track rentals lined up this year at Keystone Raceway (formerly Pittsburgh Raceway Park).

[Rob04Mach1]

AMAZING Build

[sutyak]

Originally Posted by Rob04Mach1

AMAZING Build

Thanks!

Still working on clearing out old/bad wiring. A previous owner must have had a pimp'n sound system in it. The rear mach 460 speaker deck was wired up with custom inputs, but not actually connected anywhere. Rather than attempt to rewire it I just removed the entire speaker shelf and amps to save weight. If I miss having speakers in the rear I'll pick up some 6x9's and one small amp. I forgot how heave this thing is.

[WalkrTexasRngr]

Originally Posted by sutyak

Thanks. You're welcome to come by anytime. Shoot me a PM. I think I'm going to go ahead and install the roll bar and seats, and then continue with the transmission. You should stop by SteelCityMuscleCars.com for a local forum. We have a few track rentals lined up this year at Keystone Raceway (formerly Pittsburgh Raceway Park).

Im gonna try to make one of those track rentals if I ever get my head out of my arse and finish buying all of my rearend parts. Im gonna go up to Spring Carlisle on the 23rd and see what I can find there first.

[sutyak]

Originally Posted by WalkrTexasRngr

Im gonna try to make one of those track rentals if I ever get my head out of my arse and finish buying all of my rearend parts. Im gonna go up to Spring Carlisle on the 23rd and see what I can find there first.

Awesome. I doubt I'll make it on May 6th. I know I won't be running before I finish building the new tranny.

[ASH302]

Congratulations on the build, amazing finding those used new parts from people, hope you got a good deal

ASh

[sutyak]

Originally Posted by ASH302

Congratulations on the build, amazing finding those used new parts from people, hope you got a good deal

ASh

$475 for the roll bar plus maybe $16 in gas for the drive. Much better than $600 + cost of powder coating!

Also just picked up a used set of Comp valve springs and retainers for $220 to go with my 2001 Cobra cams and Manley adjustable cam gears. Should make for a good combo to support regular 7K RPM spins at the track. Not looking for monster power, just to prevent valve float in the upper RPMs under boost.

[sutyak]

Getting some things done here and there. Mainly spending too much money on parts!

McLeod RXT and adjustable pivot ball arrived. This is one beautiful clutch! I'm really looking forward to trying a twin disc clutch. I do not like the SPEC 3+ that is in it.




The dual Walbro 255's were not fused at all from all the wire tracing I saw, so I added a couple 25 amp fuses near the battery. I probably could go down to 20 amp.


The rear seat was filthy. Dirt in every crevice. I can only assume the previous owner worked construction and left the windows down while at the work sites.
All cleaned up and pleather treated.


Comp valve springs also arrived today. They are used, but not for very long.
I believe OEM valve springs are 65lb seat pressure and 250lb/in rate
Comp springs are 90lb seat pressure and 324 lb/in rate.
Since I'm not going wild with my setup, this should match the 2001 Cobra cams just fine and allow me to not worry about any valve float under boost at 7K RPM or so.

[sutyak]

After a battle with a bad reverse switch that kept blowing fuses I was able to finally get the car inspected with functional reverse lights. For those who may need to replace their reverse sensor, be aware it goes into the transmission. Be sure to drain the fluid before trying to remove the switch. No I didn't do that, but I read a guy who did.
Next up is tweaking the tune a bit. There is a very lean spot on throttle tip-in that I need to work out.

[not a gt]

Lookin' good man

[sutyak]

I added a 45 degree coupler as a temporary solution to get the air filter a bit further away from the coolant lines. After TKat13 had his lines burst TWICE with this same turbo kit, which dumped coolant directly into the air filter. This certainly doesn't help get cooler air, but better than dumping coolant into the turbo and possibly motor.
Before:

After:


After getting more seat time in the car it seems pretty stiff for my needs. I checked the front coilovers and the springs are 12" and 250#. I'm open to suggestions on a good street/strip combo. Maybe 12" or 14" 150#? I don't mind a softer ride to help with weight transfer. I won't be carving any corners in this car. I'm not sure what shocks are on it yet.



Rears have a single-adjustable shock, but I'm not sure what brand. Springs appear to be 12" and 150# from Competition Engineering. From what I've read that should be a decent spring for street and strip? Again I'm open to suggestions.

[sutyak]

The drag radials are coming off the front of the car. I'll be selling them if anyone would be interested. I went with a set of non-directional Sumitomo HTR Z3's.




The main shaft of the transmission is completely ready. Next week I should have time to continue trans work.

[sutyak]

Playing around with gear ratio calculators, and I've decided to go with the 4.10's. I love an aggressively low gear, and with a 28" tire and a goal of 134mph in the 1/4 the 4.10's will meet my needs.
Note this is using the GeForce gear set, which has longer lower gears than the stock 3650.

4.10


3.90


3.55

[TKat13]

Looking good; glad you changed the air filter routing. BTW, it is now officially 3 times for me. Well, the first time, then the second time my hose got split in half, thinking it was an old hose I put a new one on just for the new one to blow off at WOT. The towel has been tossed and I will be pulling the motor.

I keep thinking to myself that you will soon post plans for an auto upgrade with different gears. You need to ride in an auto with that big turbo with the proper torque converter; it will make a believer out of you.

[311-420]

What if you tried to duck the filter down into that hole in the fender well where the air snorkel originally was? Coolest possible air, no chance for water to get sucked up from a blown hose.

[sutyak]

Originally Posted by 311-420

What if you tried to duck the filter down into that hole in the fender well where the air snorkel originally was? Coolest possible air, no chance for water to get sucked up from a blown hose.

Right now the cold side piping runs just inside that hole, so no room for anything to go in more than 1/2".

[TKat13]

Originally Posted by sutyak

Right now the cold side piping runs just inside that hole, so no room for anything to go in more than 1/2".

In an effort to 100% solve my issue, new braided AN lines for coolant and doing what 420 recommends and running it into the fender, but as you said, it will require redoing all the cold side piping post intercooler.

[sutyak]

Worn out stock seats out and Recaros in. The passenger side rubs the door, so I have to make some modifications to the seat mount. It looks like the seatbelt mount hits the trans tunnel. So far they are extremely comfortable and sit at stock height. I like how they sit flatter so my hamstrings aren't digging into the front of the seat when I push in the clutch.
While the seats were out I got more cleaning done, and made a couple dollars in change from running the vac under the carpet.