Monkman33's Long and Slow "Process"
 

Hey all. Some of you know me, some of you don't. I've had my FD for 7 years now, and it has never ran. Yeah, lesson learned: Don't buy a project car when you're 22 and live in an apartment. Now I am 29 and have my own house, so progress can happen from time to time.... barring getting laid off for 6 months at a time. However, members on the forums were more than willing to purchase some items from me that helped me stay afloat and keep moving forward now that I am back to work.

Over the years, my goals have been pretty liquid. But I have nailed things down to one ultimate goal:

To build my vision of an FD for today while maintaining the spirit of the original design.

So, I will post up 6 years worth of progress. Sounds like a lot... but it's really not. I will probably condense it a bit since I have to upload 1 at a time. ;-)


Here is the FD when it got delivered to my family's place. (Remember: Dumb 22 year old in an apartment, burdening his family with his own poor choices)

http://rotarycarclub.com/rotary_foru...1&d=1373135510

http://rotarycarclub.com/rotary_foru...1&d=1373135510

http://rotarycarclub.com/rotary_foru...1&d=1373135510

http://rotarycarclub.com/rotary_foru...1&d=1373135510

http://rotarycarclub.com/rotary_foru...1&d=1373135510

Here are some pics of the teardown. I had actually bought a brand new engine from Malloy originally. However, i sold that to pay for a wedding... (that didn't last). Another lesson learned.

http://rotarycarclub.com/rotary_foru...1&d=1373135890

http://rotarycarclub.com/rotary_foru...1&d=1373135890

http://rotarycarclub.com/rotary_foru...1&d=1373135890

http://rotarycarclub.com/rotary_foru...1&d=1373135890

http://rotarycarclub.com/rotary_foru...1&d=1373135890

Here are some pics of stripping the engine down. Originally, I was just going to put it all back together as it was. Then I got carried away.

It was insane how much debris was found in the turbos themselves later on. I just never got a good picture of that.

http://rotarycarclub.com/rotary_foru...1&d=1373136155

http://rotarycarclub.com/rotary_foru...1&d=1373136155

http://rotarycarclub.com/rotary_foru...1&d=1373136155

http://rotarycarclub.com/rotary_foru...1&d=1373136155

http://rotarycarclub.com/rotary_foru...1&d=1373136155

And here is her second home. She then went to a garage at an apartment complex. Then to a storage unit. Then to the garage she is in now.

Transmission
 

Transmission:
This thing came in a bunch of boxes inside the car on delivery day. These pics span 7 years.

http://rotarycarclub.com/rotary_foru...1&d=1373136581

Also, how long will Neo Synthetic stay good for? I may have a 7 year old gallon of it...

http://rotarycarclub.com/rotary_foru...1&d=1373136581

http://rotarycarclub.com/rotary_foru...1&d=1373136581

http://rotarycarclub.com/rotary_foru...1&d=1373136581

http://rotarycarclub.com/rotary_foru...1&d=1373136581

Yeah, I know, I was totally going ghetto on this. But it was 7 years ago, so cut me a little slack.

Transmission Cont.
 

So I got the main stack of 1st through 4th installed. But after 6 years, I didn't know where I was at in the process and I didn't have the space in my garage to finish it up. So I cheated and took it to a shop to finish it up. He said the good news is that I had assembled everything properly, so it was an easy gig for him top close it up. He charged me a very fair number and sent me on my way. After all, he said I had already done the hard part.

http://rotarycarclub.com/rotary_foru...1&d=1373137009

http://rotarycarclub.com/rotary_foru...1&d=1373137009

Dropped it off at American Transmission at this point:

http://rotarycarclub.com/rotary_foru...1&d=1373137009

http://rotarycarclub.com/rotary_foru...1&d=1373137009

And here it is. All done and in my packed garage.

http://rotarycarclub.com/rotary_foru...1&d=1373137009

Here is my garage today. (well, not today, there is a pile of carpets in the work area along with a dash at the current moment)

http://rotarycarclub.com/rotary_foru...1&d=1373137470

http://rotarycarclub.com/rotary_foru...1&d=1373137470

The next batch of pictures of the engine assembly is from IRP.

Engine specs:
9.7:1 induction hardened rotors from rotaryengine.com
Rotors have been lightened and balanced by rotaryengine.com
water jacket mods, oil passage mods, porting and assembly by IRP

http://rotarycarclub.com/rotary_foru...1&d=1373137470

http://rotarycarclub.com/rotary_foru...1&d=1373137470

http://rotarycarclub.com/rotary_foru...1&d=1373137470

http://rotarycarclub.com/rotary_foru...1&d=1373137840

http://rotarycarclub.com/rotary_foru...1&d=1373137840

http://rotarycarclub.com/rotary_foru...1&d=1373137840

http://rotarycarclub.com/rotary_foru...1&d=1373137840

http://rotarycarclub.com/rotary_foru...1&d=1373137840

http://rotarycarclub.com/rotary_foru...1&d=1373138495

http://rotarycarclub.com/rotary_foru...1&d=1373138495

http://rotarycarclub.com/rotary_foru...1&d=1373138495

http://rotarycarclub.com/rotary_foru...1&d=1373138495

http://rotarycarclub.com/rotary_foru...1&d=1373138495

http://rotarycarclub.com/rotary_foru...1&d=1373138643

http://rotarycarclub.com/rotary_foru...1&d=1373138643

http://rotarycarclub.com/rotary_foru...1&d=1373138643

http://rotarycarclub.com/rotary_foru...1&d=1373138643

http://rotarycarclub.com/rotary_foru...1&d=1373138643

http://rotarycarclub.com/rotary_foru...1&d=1373138763

http://rotarycarclub.com/rotary_foru...1&d=1373138763

http://rotarycarclub.com/rotary_foru...1&d=1373138763

http://rotarycarclub.com/rotary_foru...1&d=1373138763

http://rotarycarclub.com/rotary_foru...1&d=1373138763

http://rotarycarclub.com/rotary_foru...1&d=1373138898

http://rotarycarclub.com/rotary_foru...1&d=1373138898

http://rotarycarclub.com/rotary_foru...1&d=1373138898

http://rotarycarclub.com/rotary_foru...1&d=1373138898

http://rotarycarclub.com/rotary_foru...1&d=1373138898

http://rotarycarclub.com/rotary_foru...1&d=1373139127

http://rotarycarclub.com/rotary_foru...1&d=1373139127

http://rotarycarclub.com/rotary_foru...1&d=1373139127


It's a good thing that Rich sent it out with a scrap oil pan on it. the pallet broke and damaged the pan even more to where I had to bend it out of the way of the pan bolts.
http://rotarycarclub.com/rotary_foru...1&d=1373139127

Installed the Xcessive oil pan, but I might be pulling it off to add some baffling.

http://rotarycarclub.com/rotary_foru...1&d=1373220249

Noltec Motor Mounts - these may be up for sale soon, as there is something else in the works.

http://rotarycarclub.com/rotary_foru...1&d=1373220249

Zeeshan Oil Filler Neck and ReSpeed oil filter pedestal (pedestal may get replaced with something else too)

http://rotarycarclub.com/rotary_foru...1&d=1373220249

The RA OMP Adapter: It didn't fit so I had to ream one of the mountingholes out a bit.

http://rotarycarclub.com/rotary_foru...1&d=1373220249

http://rotarycarclub.com/rotary_foru...1&d=1373220249

FFE 60-2 Trigger Wheel:

http://rotarycarclub.com/rotary_foru...1&d=1373220553

FFE Primary Fuel Rail: I ended up using the riser piece to tap in the injector adapter pieces. worked extremely well. Will probably need a slide hammer/pilot bearing removal tool to get them out) And not a good picture of them, but those are ID1000's that I purchased from FFE as well.

http://rotarycarclub.com/rotary_foru...1&d=1373220553

http://rotarycarclub.com/rotary_foru...1&d=1373220553

http://rotarycarclub.com/rotary_foru...1&d=1373220553

http://rotarycarclub.com/rotary_foru...1&d=1373220553

I went to test fit the exhaust manifold/turbos/lim and found an exhaust stud that haad been damaged. probably when the pallet broke. It was just spinning/pulling out of the housing when I tightened it down to 20ft/lbs.

So, here is a down and dirty process of fixing that problem. I was a bit nervous, because if I messed this up, my only next option was a Big-Sert. if I messed that up, it was replacing a housing time. Not my idea of fun... nor cheap. And just so everyone knows, this was my first time ever doing a helicoil.

http://rotarycarclub.com/rotary_foru...1&d=1373220874

http://rotarycarclub.com/rotary_foru...1&d=1373220874

http://rotarycarclub.com/rotary_foru...1&d=1373220874

http://rotarycarclub.com/rotary_foru...1&d=1373220874

http://rotarycarclub.com/rotary_foru...1&d=1373220874