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Z Re-builds Rebuilding your ZX? Post about it here. This is for major rebuild threads only, minor mods and tech questions still go in Z Related Technical

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Old 28-10-2015, 08:40 PM   #1
MikeZ32
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My Zed, with some improvements

Hey all, some of you may or may not know my zed. It's been around the Vic group for a while now.

My old NA motor had some valve train issues, a well built motor (ex badxtc) came up for sale, I decided to swap and improve instead of repair. Having known Alex for a while now I bought the motor with confidence.

Started the swap in June, working on it slowly during my spare time, work kept getting in the way as I often have to work weekends. Finished everything this week and she's a bit different on the outside, a lot different on the inside. I've always loved the original series 1 look, body is stock and amber indicators looks great on red zeds IMO.

List of parts:

- Early '93 series 1 TT motor (Manual cams)
- Ported heads with head studs
- 1mm oversized stainless Fererra valves, 5 angle intake, 3 angle exhaust
- Forged Cosworth pistons, standard bore. 4 thou piston to bore
- Blueprinted and balanced bottom end
- Match ported upper and lower plenums
- 60mm throttle bodies with porting to suit
- Heavy duty valve springs
- Powder coated plenum
- 850cc injectors with 300 degree rail
- Mike Smith manifolds
- GT2560R turbos w/ billlet wheels
- rob260 custom split 3" dumps
- Custom mandrel bent 2.5" twin system
- UAS centre muffler
- Magnaflow mufflers and high flow cats
- Ash Spec V1 2.5" intake piping
- Blitz Dual SBC-R electronic boost controller
- Nistune Type 2
- AIV, EGR, PCV, PRVR removal
- Stainless 1L catch can w/ 1/2" barbs
- BDE alloy alternator mount
- BDE goose honk killers w/ stock recircs
- Z1 thermostatic oil sandwich plate
- NA oil filter tree
- Setrab oil cooler


- Carbing front strut brace
- Tein Monoflex coilovers F 9KG, R 7KG
- Tuneagent midori style front camber arms
- Tuneagent R spec rear camber arms
- Tuneagent pillowball tension rods
- Chili brake master cylinder brace
- R33 GTR Brembo calipers (repainted red)
- Endless 2 piece GTR sized rotors
- DBA 4000 rear rotors
- Endless MX72 pads all round
- NISMO LMGT4 18 x 8.5 F, 18 x 9.5 R
- ADVAN AD08R 245 F, 265 R

- Retrimmed interior in velour
- BRIDE fixed back bucket seats
- Nardi 350mm deep corn
- NRG quick flip
- IMPUL rear wing
- 5000K HIDs
- Yellow Jspec fog lights
- LED parkers
- Jspec side markers
- Rolled guards



Results below:

- Turbos are GT2560R w/ billet compressor wheels (Small GTX hybrids which are a new CZP kit)

Car made 363rwkw @ 23psi and 670nm from 4500rpm (I haven't even used this setting yet). 343rwkw at 20psi and 600nm from 4500rpm (used briefly but the rear still gets loose at the top of 3rd even on semis). All tuned on BP 98 although I have to say the rate the car now uses fuel almost seems like it's on E85.



Most of the time I'm using the 17.5psi setting which is around the 300rwkw mark. Trent at Chequered Tuning did a great job, gains to be had at every bump in boost but at 23psi it's at the limit of the coolers (Japtek massives / James007 mofo). As suspected, we were limited by intake temps.


Needed fatter rubber so the 17" LMGT4s are now off the car and upgraded to some wider 18" LMGT4s (I'm a fanboy). Refinished in Formula Silver which is a limited edition TE37 colour. Wearing ADVAN AD08R rubber.



















Photo dump of the progress along the way, image count warning!!!

Day myself and Sandeep went to pickup the motor. She's a bit dirty but that's how I like it.


Bits from COZ have arrived.




Old engine coming out.






Pulled dash, full aircon removal and brand new engine loom going in.


rob260's custom dumps. These are an awesome piece of kit.






NA lump coming out.




Prepping the engine on the stand.


New wiring loom going in and dash back together.









Changed the NA fuel pump to stock TT pump. Reused all the ancillary parts.





Ceramic coated the dumps and also MSP manifolds locally.







Tur bros.





Nismo copper mix twin plate.







New motor back in the car.







Accessories on, intercoolers on.







New Koyo rad going in.






Rebuilding the stock recircs using the BDE kit to hold more boost.






Love cable ties (these don't leak btw)


Turbosmart fuel pressure reg, very happy with the setup, looks stock(ish)











Adding Setrab oil cooler. Had to insert some rivet nuts as the NA doesn't have any threads but does have predrilled holes.













Damn LHD fittings, 120 deg fittings don't fit due to steering rack fouling so changed to Speedflow 1x straight & 1x 45 deg fitting.









Getting close now.







Nearly ready to start her up!







All done and she's finally out after 4 months.



Getting the new 3" dumps mated to the existing 2.5" system.





Chequered Tuning doing their magic.







Finally getting her new shoes on.











Waiting for my front tyres to be delivered to Melb as they had no stock locally.





Z needs to start sharing her space now. Spoilt rotten in the garage for too long.





Backed one side onto the sidewalk to check clearance. Clears, just barely.







And that's it really Thanks to the couple of members who lent a hand. You know who you are.
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Last edited by MikeZ32; 28-10-2015 at 09:10 PM..
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Old 28-10-2015, 08:48 PM   #2
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LOVE IT!!! Was wondering where Alex's old engine ended up
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Old 28-10-2015, 09:03 PM   #3
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Well....

Well **** me, that's impressive ! I had no idea this was going on! It was great to see you and Chris on Sunday, but I had wondered where your car was Bloody amazing job. Did you do it solo or have some help with all the engine pulling, assembly, installation etc etc? And what computer / ECU do you have in there now?

Either way, great effort, looking forward to seeing her on the road. Will your Zed be at GOR in 4 weeks time?
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Old 28-10-2015, 09:05 PM   #4
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Originally Posted by JEDI-77 View Post
Well **** me, that's impressive ! I had no idea this was going on! It was great to see you and Chris on Sunday, but I had wondered where your car was Bloody amazing job. Did you do it solo or have some help with all the engine pulling, assembly, installation etc etc?

Either way, great effort, looking forward to seeing her on the road. Will your Zed be at GOR in 4 weeks time?

Agreed - that looks amazing! Great stuff!
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Old 28-10-2015, 09:26 PM   #5
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Cheers Mark, I kept it quiet on purpose. Helps me focus on getting this done. Yep, I'll be at GOR but will probably need to leave early again. Work might call :\

Did pretty much most of it solo, for safety had mates here for the heavy stuff - when using the crane to get the engine in and out. Had to call in grunt to help lift the trans back on too. That was probably the hardest part of it.

There was a few electrical gremlins initially and that's when I knew I was beat and had to call in favours from those good with multimeters.
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Old 28-10-2015, 09:41 PM   #6
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Wow, this is impressive. Nice work man.

I feel like you need a spare JUN wing to go with the build though.
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Old 28-10-2015, 09:43 PM   #7
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I'm already hoarding LMGTs, no space for extra wings but if you'd like to donate it to me I'll happily keep a spare
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Old 28-10-2015, 09:55 PM   #8
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Looks awesome mate.
Post up the boost graph if you have a chance!
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Old 28-10-2015, 10:06 PM   #9
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Looks great mate! Good work
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Old 29-10-2015, 06:00 AM   #10
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Great power, I've always been curious about what those gtx2560s would make. Also i hope you have a plan on strengthening the rear end...
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Old 29-10-2015, 06:35 AM   #11
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Great work Mike, meant to ask you sunday what the story was with all this, excellent timing with your post! Definitely on my wish list, will have to pick your brain once we settle into the new house!

Loving the step up to 18's too mate!
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Old 29-10-2015, 06:51 AM   #12
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Well done. Such a nice clean finish. Loved the goodie list you have.
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Old 29-10-2015, 11:29 AM   #13
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Great job. Nice to see a long time member still making improvements
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Old 29-10-2015, 11:57 AM   #14
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yeah thats where my baby is, with a great person and its in a car that seriously deserves it , i was more then happy to for my old engine to end up with you man , you know me well and how i work , so you know you have a great powerful engine in your hands , i really would have like to see some gtx2863 with e85 in there but the 2560 will do the trick , and do it well , its still in the family as far as im concerned so this makes me happy ,
NOW YOU CAN COME RACING WITH US , hint hint nudge nudge .
great work man as always with you your car looks stupidly crazy . now with some balls as well .
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Old 29-10-2015, 12:11 PM   #15
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absolutly love it mike stunning zed one of my fav such a beuty even the s1 pulls it off, suspension done, brakes, interior, power love it man
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Old 29-10-2015, 08:55 PM   #16
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Welcome to the dark side!
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465rwkw @ 21psi - E85
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Old 29-10-2015, 09:37 PM   #17
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Well done!!! One of my favourite zeds just got even better!!! I am sure it will be worth all the time & money spend on it & the parts list sure is impressive...it looks really good
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Old 29-10-2015, 09:50 PM   #18
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Awesome work! Really well done, car is complete from head to tail.

Would love to see what the difference is with some real intercoolers. Those Japteks are cheap China crap. I happen to know a bloke selling a custom cooler designed for Zeds without A/C...
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Old 30-10-2015, 06:03 AM   #19
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Onya mike!
I'll echo what others have said about older members keeping the Z love alive.
Might just motivate me to get mine back up to scratch.
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Old 30-10-2015, 01:22 PM   #20
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dont think smic are going to cut it with the big boys anymore, im thinking of upgrading my smic's for a proper fmic setup too

- verticle core cooler
- duct from bar to cooler
- airdam/duct from cooler to rad
- vented nose for fresh air to rad

then if we wanted to go even more another duct after rad to bonnet to extract

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