• Hello Guest, welcome to the initial stages of our new platform!
    You can find some additional information about where we are in the process of migrating the board and setting up our new software here

    Thank you for being a part of our community!

(Not*) Mediocre 242

t8fanning said:
It was not a fun job, and I will not be remaking the stock return hard line.
Click to expand...


I ended up making a new 3/8" stainless return line.

My intake manifold requires the use of a remote power steering reservoir, so I put it where the fuel pressure regulator used to be and finally got rid of the stock return line and 180° fitting that I never liked the look of. I ended up 3D printing a bracket for the reservoir out of PAHT-CF. I've used it for other engine bay parts and it's been great. The only potential issue is material creep at the pinch bolt. I'll keep an eye on it, but I bet it'll be fine.



Here's the new FPR and flex fuel sensor location. I wanted it kind of hidden but still accessible to adjust fuel pressure if needed. My stock wiper washer reservoir doesn't fit with the intake so I made a bracket that bolts to the old washer reservoir mount. Eventually I'll probably need to figure out a windshield washer solution, but that's a future problem after the car drives again.



You can see the where the new return hard line pops out under the steering column:



A few of the return line clips under the car were broken and wouldn't fit the slightly larger new return line anyway so I also printed some new clips. That return line isn't going anywhere now. Please ignore the under car grime. We can't all be Mike K (unfortunately).









I also got my turbo. It's an XRE6973s. It's got a new 68.9 mm compressor and the new 73s turbine wheel. It's a lot of turbo and honestly probably more than I really need for what I'll be driving around at mostly, but I think it should light right up with 10:1 and VVTI. I'm still shocked how much room on the exhaust side of things I have compared to the intake side of things.





Here's the engine bay. The hard job of making the cooling stack is next.

 
Last edited:
Making some progress. I'm really trying to get it ready in time for IPD Garage sale, but I'm not sure that'll happen. Making an exhaust and tuning will be the big time sinks that could prevent it I think.

I am signed up for a roll racing event on June 13 so it has to be ready by then.

I'm not totally sure what I think of the end tanks I've been making. I think the passenger side is fine, but the driver side is a little tight to the throttle body. I'm considering using a 60° elbow instead of the current 45° to make the angle more favorable, but don't know if I want to modify the design or do something else. I don't have a ton of room to move the inlet/outlet of the end tanks though without really cutting into the headlight supports as the intercooler has to set in and then angle back due to lower mounting posts/grommets.

x-XSiukb-Imgur.jpg


f-RTZN8-M-Imgur.jpg


3ox-Bx-TG-Imgur.jpg


u-GZpe-U5-Imgur.jpg


t7bb4-RT-Imgur.jpg


e-X6e-KIJ-Imgur.jpg


JXFcd-KF-Imgur.jpg


I've still got a long way to go on the wiring, but I'm getting there.

R1-A8cr-W-Imgur.jpg


Cw-Oqg-I4-Imgur.jpg


7lij-Slz-Imgur.jpg
 
We're on the home stretch now (hopefully). I can't weld and I want it done right, so I'm taking the car to a guy to build me an exhaust and intercooler piping. Once that's done it should be ready for tuning.

My printed end tanks turned out pretty well in my opinion. The same guy who's going to build my exhaust welded on the end tanks to the core (thanks again @Stiggy Pop).
xqhwti5-Imgur.jpg


I ended up making a new skid plate that works with my front crossmember and extends all the way to the transmission. I also made a little piece that goes below the intercooler to the stock air dam.
Ss-SEsl0-Imgur.jpg

L4y-L9ge-Imgur.jpg


@hackster has been a huge help and has welded more than a few things for me during this swap. I couldn't have done it without him. But he welded up my new hood latch support since I cut away the original lower and mid mounts.
l5n-Ten1-Imgur.jpg


Here's the almost complete engine bay. I just threw on the old turbo inlet pipe, it's not going to stay that way.
k-G9-G3-Cq-Imgur.jpg
 
t8fanning said:
Eventually I'll probably need to figure out a windshield washer solution, but that's a future problem after the car drives again.
Click to expand...
I missed this post last year, did you decide what you're doing with it? I put mine in the passenger side rear buttcheek and ran the hose up through the inside of the car. It fits perfectly back there and the pump seems mostly up to the task for the extra run, it just takes a few beats for the fluid to get there. That said I don't keep fluid in it and I have never actually used it outside of proof-of-theory tests in the garage. But in terms of packaging I always thought it was a really clever answer.

Everything is looking great, the car is going to be an animal. You know I'm jealous of the trays/ducting. I am still waiting for the day you bite the bullet and buy a TIG machine though. I think you'd really enjoy it and there's no doubt you'd make a really skilled welder. You just need hours and hours of free time to learn which is easy to come by, right?
 
Stiggy Pop said:
I missed this post last year, did you decide what you're doing with it? I put mine in the passenger side rear buttcheek and ran the hose up through the inside of the car. It fits perfectly back there and the pump seems mostly up to the task for the extra run, it just takes a few beats for the fluid to get there.
Click to expand...
A check valve towards the end would help?
 
Stiggy Pop said:
I missed this post last year, did you decide what you're doing with it?

I am still waiting for the day you bite the bullet and buy a TIG machine though.
Click to expand...
I haven't decided yet what to do about the washer reservoir. I might try something like this since it's small, cheap, includes a pump, low risk of damage if it has issues, and I probably won't use it much.

Washer reservoir

I do think the buttcheek is a good spot for a larger reservoir though and might pursue that a bit.

I was going to buy a TIG machine for this project but then decided I didn't want this exhaust to be my first real welding project. I'm planning on getting one soon ish.
 
t8fanning said:
I haven't decided yet what to do about the washer reservoir. I might try something like this since it's small, cheap, includes a pump, low risk of damage if it has issues, and I probably won't use it much.
Click to expand...
Spray bottle and squeegee in the trunk......."The beauty of this plan is in the simplicity"........ Walter, The Big Lebowski

Seriously, the car is looking marvelous. Can't wait to see the first wet testing. Also clearly designed and built by an engineer.....(y)
 
Alex Buchka said:
I haven't had a functional washer system in my 242 for probably about a decade :e-shrug:

Also, yes you should get a TIG. Exhaust is a good starter project. Lots of welding that isn't front and center so it doesn't have to be perfect.
Click to expand...

I'll definitely get one, but based on the pictures the guy has sent me so far, I'm really happy he's building the exhaust for me. A 4" downpipe and 3.5" over the axle exhaust really looks to be tight under there and I guarantee I wouldn't have made fitment that nice with my limited cutting tools and no welding skill.
 
You must log in or register to reply here.
Back
Top