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+--- Thread: The Daytona Project (/showthread.php?tid=2636)
- CaptainHenreh - 05-18-2006
w00t!
- JustinG - 05-18-2006
OH Sweet..............Stickers
, lemme know if you need any help, im still here in the burg.
- HAULN-SS - 05-18-2006
wow...why so much dish? do you really have that much clearance issue? What's your expected C:R?
- D_Eclipse9916 - 05-19-2006
BLUEPRINT EVERYTHING!!! Dont want 3000 miles down the road your clearances not to be right and have to do everything all over again.
And goddamn, I didnt know you were gonna build your engine, how fast is this beast gonna be?
- Jeff - 05-19-2006
DJ- Well, power should be over 300 at the wheels (knock on wood). Everything is pretty much at stock spec. The Crank was std./std. polished and shot peened. The rods are also being shot peened and ARP rod bolts are being installed. The wrist pin are .003 oversized and they are going to hone the bushings to reflect that.
SS- Its a turbo engine, a low compression operation. I really don't know the compression ratio. I will try to figure that out soon. These are non-interference engines so its not about clearance.
If one were to compair this to Honda engines this would be kinda like an LS V-tec type thing. It is the larger and more robust 2.5L ES bottom end with the top and all the accessories of a Shelby 2.2L. I will do a little write up when I get home from work tonight that explaines what all is being done to the engine so you all can get it without reading 100 posts.
- Jeff - 05-19-2006
The engine we are building is a modern take on the original Super 60 package (S-60) that was available from Mopar in the 1980s. This package consisted of the following
- Stock T-II (turbo II) engine (2.2L from a car w/ stock intercooler, forged crank/rods)
- High-lift camshaft (slider/friction type)
- Mild port ÔÇÿGÔÇÖ (ÔÇ£bathtubÔÇØ) head. (OEM 1982-1986)
- Performance Computer
- ÔÇ£+40%ÔÇØ injectors
- Holly 155lph fuel pump
- Turbonetics/Mopar ÔÇ£Super 60ÔÇØ turbocharger w/ .63A/R Exhaust hosing
- ÔÇ£IndyÔÇØ intercooler
This package made 300hp/300lbft. Pretty damn good from an 8v engine with nothing but bolt-on parts. It was developed and tested by Shelby. Many people try to assemble it from used parts these days but it is so antiquated, there are ways to make more power with less money, which is what we are doing.
We started w/ a NON SHELBY 2.5L engine from an 89 Daytona ES. This engine was non-intercooled and sported the small Mitsubishi turbocharger. It was designed to be the smoother, torquier engine for the more ÔÇÿluxuryÔÇÖ ES Daytonas, Minivans, Lebarons, and others. It spools faster to its max boost of 8psi due to the smaller turbo and has more bottom end torque to make the lag less noticeable, and more v6 like.
That having been said it is not a performance engine we are dealing with here. It lacks the forged crank of the TII engine, but its cast crank is 12lbs lighter and just as strong well above 400hp. Its stock state lacks any form of performance good.
The parts and their donors-
Top end-
Head- Mildly ported ÔÇ£swirlÔÇØ head ÔÇô 89 Daytona ES*
Cam- Taft Stage 2 reground roller ÔÇô S-60 profile
Valves- Stainless steel, OEM size ÔÇô Forward Motion Performance
Springs/other valvetrain- Forward Motion Performance & OEM roller
Gaskets- Mopar Perfomance
Intake Manifold ÔÇô Mild port TII ÔÇô 89 Daytona Shelby
Exhaust Manifold ÔÇô Mild port
Bottom end-
Block- 2.5L ES bored .020 over, magnafluxed/Blueprinted ÔÇô 89 Daytona ES**
Crank- 2.5L ES stroker, cast, shotpeened w/ std bearings ÔÇô 89 Daytona ES
Rods- 2.2L TII w/ ARP rod bolts, shotpeened and realigned ÔÇô 89 Daytona Shelby
Pistons- Weisco Forged 2.5L custom pistons, +.020 ÔÇô TurbosUnleashed
Bearings- Clevite 77 main/rod
Peripherals-
Turbocharger- Turbonetics S-60 w/ modified 3in swingvalve
Computer- TurbosUnleashed Custom Calibration
Plugs/wires/coil- Magnacore 8mm, OEM Champion, MSD Blaster II
Wiring Harness- Custom ES/TII
Intercooler- 24X11X3in FMIC w/ 3in piping and Turbo-XS BOV
Exhaust- FWD performance 3in turboback
Fuel Pump/injectors/filter- 255lph Walbro, Mopar +40s, AEM at rail
I know this is long but you can see where explanation of the basis was needed. We have all the components of the S-60 package and then some. Every system has been replaced and upgraded to AT LEAST the S-60 standard. We have about 80% of all these items at a cost of about $2500. I hope this helps inform and interest people in my project, and questions or comments would be great.
*A more modern design then the G- cast head
**Balance Shafts removed
- HAULN-SS - 05-20-2006
You need to google serach for "engines virlgea calcuesat;or" and that siwl wlet you put in the figures for your pistosna snd deck higeight and whatnot, and give youbck the compressoon ration.
- D_Eclipse9916 - 05-20-2006
That was a fucked up post, oh and good move on the balance shafts. I wish I would have done that when I replaced the timing belt on my car. That crank should really give you nice feel, damn 12 pounds lighter? how heavy are they stock?
Looks like you got a lot of porting, you should have some fun with that. Cant wait to come back to the burg and see some of the progress that has been made.
- Jeff - 05-20-2006
D_Eclipse9916 Wrote:That was a fucked up post, oh and good move on the balance shafts. I wish I would have done that when I replaced the timing belt on my car. That crank should really give you nice feel, damn 12 pounds lighter? how heavy are they stock?
Looks like you got a lot of porting, you should have some fun with that. Cant wait to come back to the burg and see some of the progress that has been made.
Well, the 2.5L cast crank is a stock piece. It is 12 lbs lighter then the forged crank used in the 2.2L. When you compair them side by side you can call the 2.5L a "stroker" because all a 2.5L is is a stroked 2.2l. Thanks guys!!
- Maengelito - 05-20-2006
HAULN-SS Wrote:You need to google serach for "engines virlgea calcuesat;or" and that siwl wlet you put in the figures for your pistosna snd deck higeight and whatnot, and give youbck the compressoon ration.
you need to google search "do not post when drunk"
- Jeff - 06-14-2006
Well, the light at the end of the tunnel is growing slowly. The engine and all its parts are back from their places of going. The block is bored .020 over. All the pistons were EXACTLY the same size, so much so they didn't have to number them.
![[Image: newblocktopMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/newblocktopMedium.jpg)
![[Image: newblockfrontMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/newblockfrontMedium.jpg)
I thought it was cool to note, the Sun Service Equipment cart in the background is a 1960's air conditioner service cart. It had a place in the back to store the tank and all the lines. I removed all that and made it into a work cart with a wooden top. Very cool piece.
![[Image: newblockrearMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/newblockrearMedium.jpg)
The internals were balanced and assembled by CarQuest of Winchester, VA. They did a great job!! Pitons, rods, flywheel, and crank.
Thought this might make a nice table lamp...
![[Image: balancedcrankMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/balancedcrankMedium.jpg)
![[Image: pitsosonrodsMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/pitsosonrodsMedium.jpg)
Balanced and assembled for $162!!!!
![[Image: newpistoninhandMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/newpistoninhandMedium.jpg)
I hope to start putting it together this week. I just got done rebuilding my first automatic transmission today, so I will be starting on this next. I started painting the bolt on parts last week. Here be the waterpump, non-A/C alternator bracket, and the coolant pipe that runs to the heater switch.
![[Image: waterpumpMedium.jpg]](http://i26.photobucket.com/albums/c133/TurboOmni08/waterpumpMedium.jpg)
Sorting though all this stuff and finding all the parts if proving to be a bitch and a half!
- Feersty - 06-15-2006
Great progress Jeff. I can't wait to see this beast.
- .RJ - 06-15-2006
TurboOmni08 Wrote:Balanced and assembled for $162!!!!
Damn.
Where did you get your block work done, and how much was it? I'm going to build a block this fall, although I may be doing my own machine work
hock:Also, what type of wrist pins do those pistons/rods use? Are they the spiral lock type, or the "heat up the rod, freeze the pin and drop it in" type? If its the latter, then the assembly lube in there will cause some poblems when the motor fires up and may freeze the wrist pins.
- CaptainHenreh - 06-15-2006
Aw hell yeah!
Turbo FWD blingeriffic!
Good work man, keep us posted.
- ScottyB - 06-15-2006
holy cow he's totally gonna go so fast!
nice work Jeff, that's alot of attention to detail.
- HAULN-SS - 06-15-2006
If any of you guys are in the southern part of the state - I know a great Machinist. Lynwood Daughtery - used to do engines for Terry Labonte. I double checked his work when I got my engine back and my deck heights were dead on, the cylinder honing was dead on, and the main journals were at most .002" off from each other(the second time - the first time i had it done somewhere else and they were more like .007" off - looked like they had done it with a dremel)
- ScottyB - 06-15-2006
is that in roanoke Derek?
- WRXtranceformed - 06-15-2006
Awesome progress Jeff! Keep it up, I can't wait to see this thing back together ^_^
- Jeff - 06-15-2006
.RJ Wrote:TurboOmni08 Wrote:Balanced and assembled for $162!!!!
Damn.
Where did you get your block work done, and how much was it? I'm going to build a block this fall, although I may be doing my own machine work
Also, what type of wrist pins do those pistons/rods use? Are they the spiral lock type, or the "heat up the rod, freeze the pin and drop it in" type? If its the latter, then the assembly lube in there will cause some poblems when the motor fires up and may freeze the wrist pins.
Well, the initial machine work was done by CarQuest of Harrisonburg. The cleaned the block and head, did the valve job, assembled the head, bored the block, reconditioned the rods, and turned the crank and flywheel. The whole thing was something like $550 Now the balancing and the assembly of the rods were done by CarQuest of Winchester. That was that $160. I live right in the middle of the Shenandoah valley as measured with Harrisonburg at the southern end and Winchester at the north, both are 30-40mins from my house. I highly recommend either place. Nice guys, quality work.
As for the rods/pins they are a floating pin. .901 inches in diameter. They are spiral lock. (Insert Bling here) The turbo IIs and 2.5l commonblock engines had floating pins where as all other 2.2 and 2.5 talldecks were what is called a pressed pin. Which is a process of heating and pressing, as you mentioned.
- Jeff - 06-15-2006
Also, thanks for all the comments guys!!!