My BBY Mini Build Thread
Feb 8, 2011, 06:32 AM
#1
My BBY Mini Build Thread
So sometime last month I bought this bad a$$ 2003 Evo VIII. BBY with some massive upgrades. The car was originally built by Kasey Harris formerly MAP and formerly spoolinup. Here's a run down of the build by Kasey Harris.
MAP 2.4L 1400hd Pistons
MAP Rods ACL Bearings with oil squirters
MAP Rev 3 Intake manifold
MAP Stage 5 ported head
FIC 2150cc Injectors
Perrin Fuel Rail
GM 3 inch maf and maf translator
FP red 64mm
Spark tech coil on plug ignition
ETS 4 inch IC, lower and upper pipe
evo 9 bov (crushed)
MAP o2 downpipe combo with external dump
GSC custom cams
GSC beehive valve springs and titanium retainers with chrome moly seats
HKS Intake
HKS EVC6 EBC
EXEDY Twin DISC Clutch (500 Miles)
tranny completely rebuilt
Custom powder coated stock wheels
AEM Air/fuel, true boost, oil pressure in dash
And a few other misc things.... This is a pic as she sat when I picked her up.
MAP 2.4L 1400hd Pistons
MAP Rods ACL Bearings with oil squirters
MAP Rev 3 Intake manifold
MAP Stage 5 ported head
FIC 2150cc Injectors
Perrin Fuel Rail
GM 3 inch maf and maf translator
FP red 64mm
Spark tech coil on plug ignition
ETS 4 inch IC, lower and upper pipe
evo 9 bov (crushed)
MAP o2 downpipe combo with external dump
GSC custom cams
GSC beehive valve springs and titanium retainers with chrome moly seats
HKS Intake
HKS EVC6 EBC
EXEDY Twin DISC Clutch (500 Miles)
tranny completely rebuilt
Custom powder coated stock wheels
AEM Air/fuel, true boost, oil pressure in dash
And a few other misc things.... This is a pic as she sat when I picked her up.
Last edited by GrnEVO; Feb 11, 2011 at 07:10 AM.
Feb 8, 2011, 06:32 AM
#2
So the car started acting crazy about a week after I bought her. I talked to Kasey Harris and he said he knew the car really needed a tune. So I decided to turn down the boost and drive her like a grandma.
This is how she sat a week after I bought her... (Added ARC Heat Shield)
I removed the HKS EVC6 and I hooked up the AEM TruBoost, the right way. Previous owner didn't know what was up. Then I tuned the gauge the right way and was running my spring crack pressure at 8 and a duty cycle of 45 which gave me 23psi. Seemed pretty good.
Later on that same week, I was having some wierd driving issues. Sputtering when coming out of 1st. Lots of backfire shifting 2nd to 3rd Cold start would raise the idle to like 3k then taper back down to 1.1k and steady out. During driving, in between gears, the car would rev itself. Could be a number of things at this point.
So I do the usual thing anyone would do, TOTAL maintenance. Complete fluid change, spark plugs, IAC cleaning, air filter cleaning, TB cleaning, etc. The spark plugs were black as night, the TB and IAC were full of carbon, the air filter was pretty dirty, the oil was black as night, etc.
The previous owner was running Mobil 1 10w30, I decided to bump it up to Mobil 1 15w50.
Later in the week, things were still not right. I removed the intake to check the turbo and holy crap.... axial play around 1/8" - 1/4" and radial play around a 1/16". This much play is rediculous. Blown thrust bearings for sure. I contacted Forced Performance and they determined a DEFINITE rebuild was in order.
This is how she sat a week after I bought her... (Added ARC Heat Shield)
I removed the HKS EVC6 and I hooked up the AEM TruBoost, the right way. Previous owner didn't know what was up. Then I tuned the gauge the right way and was running my spring crack pressure at 8 and a duty cycle of 45 which gave me 23psi. Seemed pretty good.
Later on that same week, I was having some wierd driving issues. Sputtering when coming out of 1st. Lots of backfire shifting 2nd to 3rd Cold start would raise the idle to like 3k then taper back down to 1.1k and steady out. During driving, in between gears, the car would rev itself. Could be a number of things at this point.
So I do the usual thing anyone would do, TOTAL maintenance. Complete fluid change, spark plugs, IAC cleaning, air filter cleaning, TB cleaning, etc. The spark plugs were black as night, the TB and IAC were full of carbon, the air filter was pretty dirty, the oil was black as night, etc.
The previous owner was running Mobil 1 10w30, I decided to bump it up to Mobil 1 15w50.
Later in the week, things were still not right. I removed the intake to check the turbo and holy crap.... axial play around 1/8" - 1/4" and radial play around a 1/16". This much play is rediculous. Blown thrust bearings for sure. I contacted Forced Performance and they determined a DEFINITE rebuild was in order.
Last edited by GrnEVO; Feb 9, 2011 at 05:41 AM.
Feb 8, 2011, 06:33 AM
#4
I did find some small metal shavings on the cold side of the FMIC. As far as I could tell, the metal shavings never made it to the MAF let alone the block. When I drained the fluids I checked the oil and found no sign of metal shavings. Could be good or bad I dunno yet.
Last edited by GrnEVO; Feb 9, 2011 at 05:45 AM.
Feb 8, 2011, 06:34 AM
#5
UPDATE ....
Here's the list of parts that are finally on the way and that should all be here by Tuesday as well as what I've already gotten and installed.
On the way:
FP Green HTA w/ 18psi WGA
Evo 8 Gen2 install kit
All new hardware (turbo bolts, manifold studs, o2 housing bolts, exhaust bolts)
Mr. Gasket copper EM gasket
New exhaust gaskets (all around)
Megan o2 Housing
Megan Downpipe
some no name Test pipe
More Vibrant hoses
JM Oil catch can
JM Coolant Tank
Mishimoto Air Diverter
STM Radiator Brackets
RP 20w50
Denso BPR7ES plugs
DEI Wrap
DEI Coating
Already Installed or already have(will have pics soon)
ETS UICP, gloss black, Tial flange (will explain)
Turbosmart Race Port BOV
ETS Hard upper rad pipe, gloss black
Dejon Tool Intake, gloss black
Amsoil 3051 Filter
And the wire tuck was sort of crappy so I went back through and had to do some "re-organizing"
So like I said, here I am explaining the freaking BOV and Tial flange. Now I'm not blaming Adam from MAP but he said the TS BOV would work with the Tial flange. Maybe the old flange DID work with this BOV at some point but it doesn't now. I didn't have the time to send the BOV back and wait for a Tial and I really wanted the TS. So I decided to make it work.
Here's what the problem is and how to fix it. There is a small lip on the Tial flange that is designed to fit into the Tial BOV. The TS setup is the exact opposite. The TS BOV has a small lip on the bottom that fits into it's own flange. Now this makes it too wide to fit the v-band coupler on and won't seat with an air tight seal. Obviously won't fit without modification. So I decided to shave the lip off of the BOV using a flat table grinder and a palm sander. It actually shaved flush within about 10 minutes of work. Then I had to use my router with a grinding bit and sanding bit in order to widen the bottom hole that would seat on the flange. This was about an hour process to get it to the right radius and to smooth everything out. Now I have to hit up the lip on the Tial flange in order for it to make a proper seal. Now a little bit of gasket maker (I do this anyway on all BOVs at the flange) and we're done.
Here's the list of parts that are finally on the way and that should all be here by Tuesday as well as what I've already gotten and installed.
On the way:
FP Green HTA w/ 18psi WGA
Evo 8 Gen2 install kit
All new hardware (turbo bolts, manifold studs, o2 housing bolts, exhaust bolts)
Mr. Gasket copper EM gasket
New exhaust gaskets (all around)
Megan o2 Housing
Megan Downpipe
some no name Test pipe
More Vibrant hoses
JM Oil catch can
JM Coolant Tank
Mishimoto Air Diverter
STM Radiator Brackets
RP 20w50
Denso BPR7ES plugs
DEI Wrap
DEI Coating
Already Installed or already have(will have pics soon)
ETS UICP, gloss black, Tial flange (will explain)
Turbosmart Race Port BOV
ETS Hard upper rad pipe, gloss black
Dejon Tool Intake, gloss black
Amsoil 3051 Filter
And the wire tuck was sort of crappy so I went back through and had to do some "re-organizing"
So like I said, here I am explaining the freaking BOV and Tial flange. Now I'm not blaming Adam from MAP but he said the TS BOV would work with the Tial flange. Maybe the old flange DID work with this BOV at some point but it doesn't now. I didn't have the time to send the BOV back and wait for a Tial and I really wanted the TS. So I decided to make it work.
Here's what the problem is and how to fix it. There is a small lip on the Tial flange that is designed to fit into the Tial BOV. The TS setup is the exact opposite. The TS BOV has a small lip on the bottom that fits into it's own flange. Now this makes it too wide to fit the v-band coupler on and won't seat with an air tight seal. Obviously won't fit without modification. So I decided to shave the lip off of the BOV using a flat table grinder and a palm sander. It actually shaved flush within about 10 minutes of work. Then I had to use my router with a grinding bit and sanding bit in order to widen the bottom hole that would seat on the flange. This was about an hour process to get it to the right radius and to smooth everything out. Now I have to hit up the lip on the Tial flange in order for it to make a proper seal. Now a little bit of gasket maker (I do this anyway on all BOVs at the flange) and we're done.
Last edited by GrnEVO; Feb 11, 2011 at 09:40 AM.
