Monkman33's Long and Slow "Process"

[Monkman33]

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)

[Monkman33]

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.

[Monkman33]

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.











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.

[Monkman33]

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



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









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

[Monkman33]

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.





Dropped it off at American Transmission at this point:





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

[Monkman33]

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)





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

[Monkman33]

[Monkman33]

[Monkman33]

[Monkman33]

[Monkman33]

[Monkman33]

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.

[Monkman33]

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



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



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.

[Monkman33]

FFE 60-2 Trigger Wheel:



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.

[Monkman33]

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.