My 1981 Dodge Challenger aka sapporo project begins

city hunter · **Posted:** Sat Feb 14, 2009 12:49 am

lol, I just grabbed that out of the dumpster.

I picked up my friend johns prototype starion intercoolercomplete bolt in set he developed but never put into production due to lack of interest.

The intercooler is 100% fabricated in washington by john. Side tanks hard pipes etc.. The core measurements are around 31x12x4 plus end tanks I believe. I havent measured it out. It's designed to bolt into straight into a tbi setup, but he would also fab my up the hard pipes for a mpi setup as well.

He said the intercooler should be good for 900hp or so as this was the same size they were using on the mk4 supras. Either way it's overkill for a tbi, but what the hell, it's so much nicer than my chiense one, weighs less and will hold more pressure

.

I plan on tossing this bad boy into the lambda for the time being. Now if I can just get a t3 manifold and my friends hy35... :bootyshake:

Arrow Joe · **Posted:** Sat Feb 14, 2009 1:47 am

Looks great, the welds on that intercooler are superb.

Also, you're a colossal weeaboo.

city hunter · **Posted:** Sat Feb 14, 2009 3:02 am

dunnmo what a weeaboo is lol.

Yeah my friend john has been welding aluminum for a long long time. He built so many intercoolers for Extreme turbocharger systems. He ended up quiting there due to some fallout wiht the owner and has been doing some fab somewhere else, but I guess he is going to be starting his own buisness soon. It's just kinda cool to use something a good friend has made and even better is the nice quality.

ben · **Posted:** Sat Feb 14, 2009 11:56 am

Random question: what's that GTO dvd set in the back? I'm hoping it's a Japanese anime series starring a Galant GTO

RedSunday · **Posted:** Sat Feb 14, 2009 1:11 pm

ben wrote:

Random question: what's that GTO dvd set in the back? I'm hoping it's a Japanese anime series starring a Galant GTO

Nah I got all excited about that too, but its about a guy on a motorbike or something..

Cool project btw!

weeaboo
http://www.urbandictionary.com/define.p ... rm=weeaboo

I hope he means this one lol!
weeabo
http://www.urbandictionary.com/define.php?term=weeabo

MonkeyMadness · **Posted:** Sat Feb 14, 2009 11:28 pm

^Hay Redsunday I too have a jdm balanced sump plug^

city hunter · **Posted:** Wed Feb 18, 2009 12:57 am

Well, I made some decent progress today. I fabbed up some mounts for the transmission and got the meausrements for how much longer my driveshaft needs to be. I need to go snag some retainer clips from the jyard tomorrow for the outter mount. The only thing left is to mount the clutch pedal, which I am procrastinating on. It should get done tomorrow though. I also need to drop the gas tank tonight and see if my starion tank will fit. I have a feeling there is some sludge buildup in this tank as it has been sitting forever.

Back to the garage. I gotta get as much done as I can before i get too drunk.

city hunter · **Posted:** Wed Feb 18, 2009 9:41 pm

SPent most of the day working on the car, making some misc pieces of the transmission and piecing together a driveshaft..

Finished product is a transmission and driveshaft bolted in and ready to go. For those iunterested and state side. I used the automatic sapporo rear driveshaft with a 2.0l 1986 d50 2wd front driveshaft, and threw a PCN-398 U joint in. This makes for a bolt in driveshaft

I

Tomorrow I will check the gas tank out, replace all teh soft rubber lines with fuel nijection line and isntall te fuel pump. I'll probably get clutch anmd brake pedals mounted also. I need tog et some cutting discs and open up the shifter area of the trans tunnel as well.

With any luck I should have this on the road by saturday if I can source a stock starion oil cooler.

Stormhammer · **Posted:** Thu Feb 19, 2009 12:36 pm

I find it sad on my end that I can identify an 86/87 Starion transmission based off of its pan.

city hunter · **Posted:** Thu Feb 19, 2009 1:06 pm

yeah, all its dirty glory. It's a junky tranny but it works until I find a better one. I'll probably end up putting a 88 transmission in later. I have one laying around but I lost ot.. Dont ask me how you lose a transmission... lol

city hunter · **Posted:** Fri Feb 20, 2009 1:02 am

yeah it happens lol. I have a 88 tranny with a 87 pan laying around somewhere.

Well, I Should have the fuel pump mounted tomorrow. I'm going to do a trunk mount as I have plenty of room and I dont want to dropt eh tank. I drained it and there wasnt varnish in it, so good enough.

city hunter · **Posted:** Mon Mar 02, 2009 3:24 am

not a whole lot of update. I've been messing with the small things lately.

I've got about 75% of the engine bay cleaned up. I jsut have the back portion left.

I also test fitted some of the starion turbo door handles. They almost fit perfect, about a 10th of a inch off from sitting flush. While test fitting, I tried to adjust the door hinge rod and broke it off because it was so f;n rusted. Now I gotta open the door fromt he passenger side. Hells yeah. I'm pretty sure a starion rod will work though.

I also spent most of the night checking the few cylinder heads I have. The 2 I had loose both had cracks on cylinders 2 and 3. The one I took off the original engine looks good, but I will need to put some new valve seals in at least. It's all cleaned up and about ready to toss on.

I'm ehading up to monroe this week to grab starion front suspension for the car. Should be quite the upgrade over the stock solid rotor bullshit.

fuel · **Posted:** Mon Mar 02, 2009 12:10 pm

progress is coming along quickly!

what's the difference between an 86/87 and 88 trans?

city hunter · **Posted:** Mon Mar 02, 2009 12:33 pm

a cast aluminum wafled bottom oilpan cover, the gears are also wider physically so they can hold more power.

city hunter · **Posted:** Tue Mar 03, 2009 2:56 am

DId a little more work tonight with some motivation

city hunter · **Posted:** Mon Mar 16, 2009 2:48 am

I actually made some decent progress today.

I installed drilled out some brackets, drilled out holes for the clutcvh master and pedal, and mounted the pedal to the firewall. I still have to weld in a mount for the upper pedal mount.

I also pulled some of the blower motors off and installed the wiring harness I got from jeff.

The heron exhaust I will be using on my car. Well only part of it

She is a bit naked up front also. I needed to pull the bumper off tog et the fender off and do some test fitting of the intercooler.

city hunter · **Posted:** Wed Mar 18, 2009 3:23 am

Made some progress tonight. I managed to get the intercooler mocked up and holes cut in teh front core area, opened up the transmission tunnel area, and cut my fucking wiring harness so I had to install a different one. I also intsalled the fender and lower airdam thing along with the bumper and grill for some mock up to ensure everything fits.

Clutch pedal mostly mounted. I sitll need to weld in some mounts for the top

In trunk fuel pump mounted

The wonderful job I did cutting my perfect harness

A picture of my aus taillights I received the other day.

Opened up transmission tunnel

Mock up of the intercooler with holes cut and a fiero radiator.

Front end tested with hood latch suppose in place and bumper with intercooler sitting in there.

Under lip installed

You wouldnt even know this thing was turbo charged

city hunter · **Posted:** Sun Mar 29, 2009 2:55 am

Not much of a updatre but I made some progress tonight.

I got my new oem water banjo washers for the turbo, oilcooler banjo washers, and turbo gasket set.

I spent most of the night playing with the turbo figuring out where to clock it. The 14b has htis annoying notch on the cartridge and a pin on the compressor housing so it can only be installed one way. I had to file a new notch into the cartridge as I have it clocked way off from factory.

Anyhow, pic is of my 14b turbo mounted in a td05 housing ground out for a td05h wheel. This turbo should be fine for the time being. I know with the evo 3 housing these turbos will flow 300rwhp. I figure if I can get 250rwhp I will be happy. I know my torqu will be over 300 with some luck

I also installed the water linues for the heater core. Along with that I cut some of the cloth intercooler pipes to fit my intercooler configuration.

The only thing I have left in the engine bay right now is the following.

-Install starter
-Install dizzy
-install new vc gasket
-Secure starion wiring harness
-Install coil
-trim stock harness so it only fires the starter, or run the starion starter trigger. I'm undecided.
-Make some simple radiator mounts for the fiero radiator and tie in a puller fan.
-make a small oil cooler mount
-bolt the grill and bumper back on
-install the new pcv hose
-install a 1 way valve between the intake and booster off a starion
-install fuel filter, feed and return lines

Basically a ton of small things I can wrap up in a day easily.

Other things I still have to do with the car.

Interior
-reinstall blower motor
-clean and paint the dash parts
-install some black starion carpet
-install starion seats
-paint and clean the entire interior trim

Misc
-install banjo for the slave cylinder
-weld in the upper mount for the clutch pedal
-install clutch pedal to master rod
-redo all the brakes and flush brake system
-cut and weld up my resonator and side dump exhaust
-wire the couple wires off the starion harness.
-run a fuel pump power wire off the stock starion harness

I think thats about it. I should have this baby up and running in a few days.

This is how the engine sits now. I forgot to bolt on the wastegate actuator.

city hunter · **Posted:** Fri Apr 10, 2009 1:10 am

Well a little update. I picked up a 1980 plymouth arrow sport truck the other day so its been sucking my time away but I got some more stuff done on the car before I pulled it out of the garage.

Engine is completely done everything mounted, bumper reinstalled.

The only thing i have left to do is install som,e spark plugs, plug wires, wire in a ecu pwoer with a fuse onto the battery. Thats it for the engine bay.

I also fabbed up most of the side dump exhaust. It's currently mounted and resoinator is on. I have one last straight piece to weld on, but I am waiting untl slodat gets back so I can make the last cut on his bandsaw.

To get it started I need to do the following

Wire up 2 or 3 wires from the engine harness off the b38 plug, run the pwoer wire to the fuel pump.... annnnnnd put some gas in the tank.

city hunter · **Posted:** Wed Jun 10, 2009 12:50 pm

Well, been a while since a update. I'm about to fire it up. GOtta go solder 2 more wires, put the accordian hose back on and toss some water in the radiator.

My 1981 Dodge Challenger aka sapporo project begins

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