infernosg's S5 N/A Build

[infernosg]

It's been a while. Time for an update.

The pedal was still too soft for my liking so I wanted to add another spring. The APC bracket was too short so I made another using it as a template. It's still a little rough but the pedal is nice and firm now.



I realized I didn't need the second circuit breaker in the engine bay so I replaced it with a single post terminal. This got rid of the weird loop in the starter cable and made it shorter. More clearance between the main harness and the alternator now too. I also found a neat cover-thing to prevent any shorts.



While I'm waiting for my exhaust manifold to be completed I started cleaning and painting various engine pieces. Nothing crazy. Aluminum pieces painted "aluminum" and iron pieces will be painted "iron."

Alternator and new dual sheave pulley:



Water pump housing:



Masking/painted rotor housing:





Alternator relocation bracket (still need to paint the slide):



Blocked off oil metering pump on front cover and painted it and the CAS:





Ordered oil pan brace and painted it black:



I also convinced myself to replace the bulk of the 23 year-old fasteners.

Bolts for water pump and front cover and washers for exhaust manifold and engine mounts:



Additional bolts for the front cover, nuts for the water pump housing, exhaust manifold, and engine mounts, and washers for the water pump housing are still on their way.

McMaster for just about everything else (all are Class 10.9 and black-coated):



Cleaned the oil pan:



Still need to remove some residual silicone/gasket material and paint.

Balanced rotating assembly came back. New main pulley and e-shaft thermal bypass delete:



F/R rotors (within 3g):



Other rotating bits (new rear counterweight on the right):



New e-shaft (RX-8) versus old:



More painting/cleaning to come. Dummy engine will come out once the exhaust manifold is test fit.

To do:
-Paint intermediate housings, intake manifold and misc brackets
-Clean engine bay
-De-power steering rack
-Duct forward side of radiator
-Make FG fan shroud
-Make extension harness for O2 sensors
-Permanently install seat/harness
-Rebuild/install engine
-Make some kind of exhaust
-Start???