My 1995 GTR project thread.

[cortexx]

Intake manifold Rebuild ...........

Actually before we go down that road i think i'll cover the exhaust manifold install , coming from Toowoomba in Australia is the now famous six boost exhaust manifold . It is a true divided pulse twin scroll design that hopefully will improve the scavenging ability of the exhaust system to increase power , and also decrease spool up time. It weighs alot but is made from 3mm steam pipe so should last me a few years . Also came with all new stud kit and new nuts and stainless T4 flange gasket ( although i turn my nose up at this a little , looks like a cometic piece).

Time to install the studs into the head using antisieze - this ensures the exhaust manifold will fall off while on the track and give amny more hours of pleasure re-assembling things . ( oh wait , that was the dump pipes to the down pipe.... ) I jest really - antisize is a must on these studs if you ever want it apart again.




exhaust gaskets next - im using the ones that came int he nissan gasket kit , ill possibly replace with stainless ones at a later date but dont have a spare set at the moment ...





Screw the chsseburger - We can has 6boost ......

[cortexx]

Actually from thsi angle you can see the cam markings that have to be aligned when installing the belt , should have posted this pic earlier ..........



so the exhaust side was pretty painless , mostly because the engine is not in the car

Intake side is taking alot of my time as perfection is the key here...

So the intake manifold assembly came to me in less than perfect condition , the nissan engine gasket set came with all the o-rings and pieces needed for a complete strip and rebuild of the intake castings so no excuses to not do things properly ...

First things first - complete disassembly of all castings , the intake manifold , the balance tube and the water return casting that runs underneath. the water return has no gaskets but relies upon metal to metal sealed with nissan RTV just like the waterpump installation. The balance tude has a series of o-rings that seal the casting to the intake and it all needs to be scrupiously clean for final assembly.

Off to the bead blasting for the intake followed by some solitary time in the ultrasonic tank to remove any and all residues and particles . Turned out really nice - looks like new metal - so i gave it a good coating of fluidfilm to stop it oxidising. Here is the unit with the new set of o-rings installed ..



The balance tube and water return castings were tanked in the toxic waste bucket of kleenflo metal cleaner to remove anything not metals , then washed in varsol , blow dried , bead blasted to aneal the metal and clean it , thrown in the ultrasonic tank to really clean them and then painted the same epoxy paint the block was painted with ...

balance tube reinstalled to manifold with new allen bolt fittings ..



The water return casting has a nasty case of corroded nipple , so i decided to fix it incase it leaked . Delaing with this at the back of the engine once installed is not my idea of a relaxing evening .. do it once - do it right ...

it's ugly i warn you ..



so i cut off the nipple and discarded the nasty part with my dremel ...



I then punched out the remaining brass insert and tapped a nice new pipe thread into a fresh aluminium ....



Looks alot nicer , went to Canadian tire and bought a $3.50 brass fitting from the plumbing section spread some Nissan RTV sealer over the threads to make sure it's watertight and assembled it ..



A nice cheap repair that should hold up for another 17 years



Incidentally to make sure the threads don't leak from the inside ( antifreeze is very searching ) , i trickled some red threadlock down the threads from the inside of the casting ... not the best picture but you get the idea ..



once this was completed the casting was treated to the epoxy block paint and assembled to the intake manifold . Looks nice and clean in 1 piece and the contrasting colour really makes the aluminium pop out

The 3 castings are torqued down together to ensure that there is no warpage caused by uneven bolt tighteneing





Here is the finished assembly with a nice new Tomei stainless intake monifold gasket ready for install to the cylinder head ...



Once again the mundane and dirty fasteners were replaced with much nicer allen headed bolts of the appropriate sizes , i also used lock washers on these fittings for a tight and secure assembly.

After this evenings work i decided to mount the ITB's and the Nismo plenum i intend to use purely for an idea of what it will all look like when it's together - here is the engine build todate ...... more updates soon (tm)

[ColinR33]

Damn. That is sexy. Can you come out to Edmonton and help me with mine?

[cortexx]

I would however , i would hate to deprive you of the pleasure of building it all yourself

Damn. That is sexy. Can you come out to Edmonton and help me with mine?

[bellis_GTR]

I would however , i would hate to deprive you of the pleasure of building it all yourself

Just like it should be done!

Awesome work Paul. Love the great detail pictures. Love the autoporn!

Cam cover color?

[cortexx]

Millenium Jade ..

Just like it should be done!

Awesome work Paul. Love the great detail pictures. Love the autoporn!

Cam cover color?

[PurpleStreak]

Love the attention to detail Paul, its a wonder what those ultrasonic tanks can do! We have a contractor who cleans spools at work with them and they come out damn clean, I didn't realize you could get garage sized versions!

About the brass insert you eliminated and tapped a thread into the aluminum, you may want to flatten the surface and place a copper washer between the fitting and the aluminum, as the metric thread isn't designed to seal across it..could eliminate a headache later on!

[cortexx]

Ah yes i should have mentioned i cut a pipe thread in this casting - do you think i still need the washer? I didnt think this would leak .

[PurpleStreak]

Ohh I missed that part..it should be fine then.. I would use a thread sealant or plumbers dope instead of the RTV though as the RTV would vulcanize and may break up

[Phastwon]

Looks fantastic Paul. That is the same ATI dampner and underdrive I used. You will notice a difference in vibration for sure.

[ColinR33]

Hah! It will be quite a while before I have the guts/skill to do the level of build you are doing! I can dream for now.

I would however , i would hate to deprive you of the pleasure of building it all yourself

[R33-East]

Amazing build with incredible detail! I am excited to see the final results.

[MarusGTR]

What had happened to the engines using a fluidampr? (It was also my first choice)

Exquisite build, that's coming from someone who lives for details. Details like your waterpump pulley that was facing the wrong way but was fixed later without mention

[nimblestix]

What had happened to the engines using a fluidampr? (It was also my first choice)

Exquisite build, that's coming from someone who lives for details. Details like your waterpump pulley that was facing the wrong way but was fixed later without mention

The pulley was correct. If not then my engine is wrong too. But the belts all line up no problem.. ?

Nice build!

Sent from my Galaxy Nexus using Tapatalk 2

[MarusGTR]

The pulley was correct. If not then my engine is wrong too. But the belts all line up no problem.. ?

Nice build!

Sent from my Galaxy Nexus using Tapatalk 2

VS