Project Evo "Franken-IV" forge rebuild!

coolamasta

coolamasta

coolamasta

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Project Evo "Franken-IV" forge rebuild! (PIC HEAVY!)

Not sure if any of you guys would be interested but as I got all the pics etc up on other forums etc I thought I might stick some up on here as well :)


Quick run-down - had my Evo IV about 3.5 years now and its mostly a toy/track car/weekend run sort of car, I've replaced all sorts of parts over the years where I've broken them IE: I've managed to break 2 rear diffs, the standard one had 80k on so not surprised it broke but the VI one I replaced it with lasted under 1000 miles and destroyed itself (so much for being in mint low mileage condition eh!) so im now on a Evo VIII rear diff from a dealer rather than 2nd hand! :)

To cut a long story short, I had some gearbox woes last year, bought one, turned out to be bad so had my old one rebuilt so it needed to be swapped over again and paying out labour all the time (even though I get a good rate) was getting expensive so I decided to do it myself and then the money I would have spent on labour could be put towards an engine upgrade!

Decided to sod everything and go for it once and for all, the work im now doing while its in bits = 2.0L Forged engine internals (MA Developments build = 600bhp capable bottom end) bigger turbo, standalone ECU with anti-lag & launch control, stripping the interior, fitting a roll cage and adding a couple of racing seats and 4-point harnesses etc etc, should be good fun! :)

A quick breakdown of what is in/on the car right now:
  • 30k Tommi-Makenin Engine
  • Evo 8 GSR 9.8T Turbo
  • Evo 6 slightly ported exhaust manifold
  • Evo 6 Gearbox currently being rebuilt as we speak
  • Rebuilt Evo 6 RS transfer box
  • Evo 8 rear AYC rear diff
  • Evo 8 Brembos all round
  • Tein Monoflex fully adjustable coilovers
  • 3" Magnex downpipe & full 3" Fujitsubo Exhaust
  • Walbro 255 fuel pump
  • Autobahn88 Large FMIC & ally piping
  • Ecutek'd Evo 5 RS ECU, 560cc injectors & Sard regulator
  • Loads of other bits and bobs
List of parts I've had sitting around for the last year+ but never had chance to think about installing:
  • 12k Mint Evo IX 80 series turbo
  • DNP (American) equal length tubular manifold
  • Apexi Power FC D-jetro ECU (might be changing for Vipec)
  • HEL 19-row oil cooler
  • Many many other parts!

Hers some pics of "Part 1 - the strip-down" :cool:

How its been for the last couple of years:
tokenpic.jpg


Bumper removed:
1.jpg


Before the part removal:
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Before the part removal:
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New HEL oil cooler brackets made ready:
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Strut-brace, Air filter, Intercooler & piping removed, Engine loom disconnected:
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Coolant drained, Radiator & pipes off, downpipe & Turbo off:
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How it was left yesterday, next stage to re-remove oil cooler, fuel rail, starter motor & alternator wiring and PAS & Aircon pump:
7.jpg


Shiny new parts list :D

sard1.jpg


oilcooler1.jpg


dnp1.jpg


dnp2.jpg


9tubby.jpg


tein1.jpg


tein2.jpg

 
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8 hours of errrr fun, a good 1.5 of them trying to disengage the damm clutch!! (instructions I had were wrong grrrrrr) :mad:

Eventually got it all out but managed to fall down a step in my garden carrying the transfer box, really badly twisted my ankle and cracked a curbstone with my elbow but saved the transfer box haha! :(

My attempt at making an "engine dolly" although seemed pretty good at the time turned out to be way too wide and not high enough! Oh and one of the castors self destructed!

The engine crane decided it didn't like my VW Golf and decided to smack it in the boot lid, needless to say I was a tad peed off so in anger I kicked the stand with my swollen ankle, then proceeded to hop about shouting loud obscenities, calmed down, had a word with myself and carried back on with it!! :eek::eek:

Anyway, some pics of the days events with a couple of mates helping me:

Quick home made engine dolly:
9.jpg


Wheels off, oil cooler & aux belt removed:
10.jpg


Drained last of fluids:
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Drive shafts popped out all ready for lowering the engine/box/tx-box:
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Engine sort of sat on dolly with some 2x4 helping balance it lol:
14.jpg


Bricks came in very handy, glad I had a load left in the garden!
15.jpg


Dolly caster = fail!!!
16.jpg


Woooop engine, gearbox and transfer all out in 1:
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Engine crane 1, VW Golf 0: :cry: :cry: :cry:
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Whos needs 400bhp when you can have 1bmp!! (he wanted the token shot) lol:
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After much swearing at the gearbox we finally got the clutch released and celebrated with some budweiser!!:
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Car how its been left for the day:
22.jpg


Engine separated from the gearbox, little bit of gearbox oil spilt!
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Engine under my work bench ready to be cleaned and further stripped ready for forging:
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I look forward to putting it all back together *cough* NOT! haha but hopefully will have a better dolly this time!

More updates to follow... :D

___________________________________________________________


Not done that much this weekend as I was at Castle Coombe Action Day on Saturday which was depressing watching everyone else enjoying their cars but still a good day none the less! lol

Anyway managed to get a bit more stripping of the engine done today, just a few pics from today:


Engine mostly stripped ready:
25.jpg


Random inlet valve shot:
26.jpg


All belt covers etc removed:
28.jpg


Boot full of removed parts!:
32.jpg


Put turbo together with HEL braided lines and MR outlet:
33.jpg




More updates to follow... :smthumbup
 
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After some thinking I decided to remove the aircon tonight and then started stripping the loom back for some fresh conduit :)

Not done that much over the last week or so as I've been busy with work but managed to repair my corroded/rusted battery tray, not an A-class job but certainly a lot better and will stop any more rust! :)

Otherwise I got some new bits and bobs arrived this week and today I put the engine in the boot of my Golf, strapped it down and wedged it in place with some wood and drive it 90 miles over to Mark (MA Developments) for its forging, I even managed to do 54mpg cruising in 6th gear around 70-75mph with it in the boot :D :cool:

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Good stuff, love these sort of threads :D

Looking forward to some updates, Does 1BMP mean what I think it does? haha
 
TaKeN said:
Good stuff, love these sort of threads :D

Looking forward to some updates, Does 1BMP mean what I think it does? haha
Click to expand...

There was only one thing I thought it could mean!

Good thread, can't wait to see some more input.
 
Very nice mate, really like the Evo 4's although its a shame they suffer from crankwalk (not that it applies to you).

Should be awesome when it's done :)

You drivetrain bills make my eyes water! I'm going to drive mine very, very carefully tonight now!

Whats the ETA for the engine?
 
Gaijin said:
Very nice mate, really like the Evo 4's although its a shame they suffer from crankwalk (not that it applies to you).

Should be awesome when it's done :)

You drivetrain bills make my eyes water! I'm going to drive mine very, very carefully tonight now!

Whats the ETA for the engine?
Click to expand...

Whats Crankwalk mate ?

Great project, will keep checking back :)
 
Sam said:
Whats Crankwalk mate ?

Great project, will keep checking back :)
Click to expand...

How often it occurs and how bad it is, is a constant debating point.

Effectively it is caused by excessive crankshaft thrust bearing wear which can make the crank get pushed into the cradle and block which causes damage to all three components.

Changing the bearing is a short term solution only, many 4's are instead fitted with evo 5-8 engines to rectify.
 
Hi all, thanks very much for the nice comments, always good to hear :)

Sam - yeah exactly what Gaijin says, the Evo 4 was the first of the Evos to have the newly designed 4G63 engine and the not so good crankshaft thrust bearing design wear would cause the crank to actually have some play/movement side to side thus making engine failure a high probability! This generally only effected high mileage or abused engines but if kept standard-ish (around 300-bhp) and well looked after then it was generally OK but unfortunately it made them less tunable and the 4's less desirable :(

When Mitsubishi brought out the Evo 5 they re-designed the thrust bearing/mains layout and so fixed the "crankwalk" problem which has stayed the same all the way through to the 9 engines but the 10 engine is a whole new kettle of fish!

I actually swapped my standard 4 engine out 2.5 years ago for the low milage Tommi Makenin engine (basically an Evo 6 engine) because I had valve seating issues with it and decided it wasn't worth fixing because I wanted to run 360bhp which the 4 engine just wouldn't do safely.

I've been running 360 now for the last couple of years but now I need more! I aiming to run 420-430bhp with the 80 series turbo I have already and then when I can afford a Full Race Garrett GT3076R Turbo kit I will be going for around 520-550bhp :D :D

Gaijin, what Evo you got mate and are you on the MLR?
 
I myself have had an white Evo 6 and a Sti 7. Japs can make fast cars! Looking very nice mate, love the colour of your IV. Just wondering why you went for TEIN coilovers? I have had nightmares with them in the past I wouldnt touch them with a barge pole! A few of mine burst had a nightmare trying to get TEIN to ship replacements to the UK. From what I here HSD are the way to go and are certainley cheap or KW. Your engine will be a beast am sure. Good look with the build!
 
Oh and this makes me miss my scooby, its been near enough 6 months since she left me :( The clio is fun but as much as i try and convince myself its just not the same :p
 
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