135is -> 1M CSL/GT4 build

[tracer bullet]

Originally Posted by Latebeemer

at the end of an afternoon of spirited road driving, this happened

FWIW, that sucks! And probably right after you were feeling pretty good about everything.

[Latebeemer]

Originally Posted by ShocknAwe

Gonna flush the engine?

I'd definitely replace everything on the hot side with new

Yes! I'll open and inspect everything, downpipe is not a problem. I'll inspect the wastegate to see if there is any damage to the valve seat, other than that it should be ok. I'll check the O2 sensor for damage also. Turbo is completely toast without having removed it yet I already know that the turbine has been rattling around in the housing because of the shaft ejecting itself out the other end so its all banged up. I for sure have to open the oil pan to clean any possible debris that came through the turbo drain and then the turbo inlet and outlet side including the intercooler.

I've already inspected the charge pipe right after it all happened and it was completely clear, there was some water/meth residue left in the pipe and it would have likely caught any dust or small particles that came through the intercooler and it was completely clear which was a great relief as you can imagine hahaha

[Latebeemer]

Originally Posted by tracer bullet

FWIW, that sucks! And probably right after you were feeling pretty good about everything.

Hahahaha Oh yes of course, I felt great about it!...

[Latebeemer]

Overspinning a turbo is definitely something to be avoided at all costs!

I found the turbine wheel in the exhaust around where the passenger seat is... it took out 2 Lambda sensors on the way out.

The compressor wheel hit the compressor housing so hard that the three securing plates are all bent. The wheel forced the compressor housing away from the turbo which is impressive for something that has such little inertia.

[Latebeemer]

It's been a while since I've posted, there has been a lot of developments. I'll pick up were I left off...

In March this year I received the new turbo, a G35-1050 with a new 1.06A/R twin scroll T4 turbine housing since the old one was destroyed.

I had the turbine housing an manifold ceramic coated and I've inspected the exhaust ports, exhaust manifold, oil pan, intercooler and everything except one thing...

Before ceramic coating I added EGT bungs for future use and a exhaust manifold pressure bung to use with the Reflex+




Installation in progress




More carnage:

[Latebeemer]

Guaranteed when you read this you are going to be yelling at the screen...

In my defense, the day the turbo blow up, I started the engine up after figuring out the turbo had blown, I might have mentioned this in an older post... the engine stared up and idled silky smooth and was quiet as it did before the turbo blowing up, there was a lot of smoke since the turbo had coated the inside of the exhaust, but other than that there was no indication that anything was wrong with the engine... coupled with me scoping the exhaust ports and seeing no marks or damage of any kind... So I finished the assembly, got everything buttoned up and pulled the plugs and injector connectors and cranked the engine until I had oil pressure, bled the coolant system and then got ready to fire the engine up for the first time in months... well here is where things didn't go so well. Upon starting the engine up, the was a ticking noise coming from the engine, loud enough to not be lifter or injector. I called a mechanic friend of mine and sent him a video... long story short I pulled the engine to start stripping it because this sounded like a piston problem.

The engine out process:





The carnage:



I dropped the engine and the head off at ARE on the Monday to see if they would be able to save it, which they said they can do.

I could kick my own a$$ for not checking the engine internally over winter, because if I did, I would have had a car to drive this season... rookie mistake

[Latebeemer]

After dropping the engine off, I had time to find things to do that I've wanted to do.

Designed and had the heat shields for the front brake ducts 3D printed, I originally wanted to fabricate them from sheet aluminum but decided 3D printing would be easier.

3D printed brake heat shields:




Next thing I wanted to do was to make an oil pickup tube that is not plastic and which I can make a baffle that blocks off the oil in the pan completely around the oil pickup, which you can't do with the stock one because of the one mounting arm/leg.

3D printed N54 oil pickup/suction tube

[Latebeemer]

I bought a used oil pan to experiment with. The goal is to increase oil capacity and baffle the pan in such a way to eliminate the oil sloshing away from the pickup under circuit usage. I do still have the accusump installed, and will keep that until I've verified that this oil pan is up to the task.

Oil pan modification commence:

[Latebeemer]

I redesigned the entire intake system all the way to the intercooler because I'm not happy with the silicone intake that I got with the speedtech kit originally, with the redesign of the manifold and the exhaust ports of the N53 head being lower, that intake pipe no longer fits properly, in never fitted nicely to be honest, and it now has a hole in it from where the turbo shaft punctured it.

N54/N53 3D printed bottom mount turbo intake system:


The plastic parts are in progress, the are easy to install even when the engine is back in the car.

As of today I'm still waiting for pistons to arrive, it's been 10 weeks since I've ordered them. +1mm oversized was a custom order, no one kept them in stock at the time I ordered and CP Carillo were the only ones with the oversized option.

I have also in the mean time purchased a spare block, crank and N53 head in order to build a spare engine in the coming year so I don't sit without a car during racing season again.

Some pics of the spare parts:

[Suprgnat]

What a series of posts! Amazing garage build!